Stapling assembly components having metal substrates and plastic bodies

ABSTRACT

A surgical stapling assembly is disclosed. The surgical stapling assembly can include a first jaw, a second jaw, an articulation joint, a closure drive comprising a first flexible rotary drive extending through the articulation joint, and a firing drive comprising a second flexible rotary drive extending through the articulation joint and rotatable independent of the first flexible rotary drive. The surgical stapling assembly can further include a 3D-printed component. The 3D-printed component can include a plastic body and one or more metal substrates with interlocking features embedded in the plastic body. The surgical stapling assembly can include a firing member having a flexible portion configured to flex more readily that adjacent portions of the firing member.

BACKGROUND

The present invention relates to surgical instruments and, in various arrangements, to surgical stapling and cutting instruments, end effectors, and staple cartridges for use therewith that are designed to staple and cut tissue.

BRIEF DESCRIPTION OF THE DRAWINGS

Various features of the embodiments described herein, together with advantages thereof, may be understood in accordance with the following description taken in conjunction with the accompanying drawings as follows:

FIG. 1 is a perspective view of a surgical stapling instrument comprising a handle, a shaft assembly, and an end effector, in accordance with at least one aspect of the present disclosure.

FIG. 2 is a perspective view of the end effector and a portion of the shaft assembly of the surgical stapling instrument of FIG. 1 , wherein the end effector is illustrated in a straight, or non-articulated, configuration, in accordance with at least one aspect of the present disclosure.

FIG. 3 is a perspective view of the end effector and a portion of the shaft assembly of the surgical stapling instrument of FIG. 1 , wherein the end effector is illustrated in an articulated configuration, in accordance with at least one aspect of the present disclosure.

FIG. 4 is an exploded perspective view of the end effector and a portion of the shaft assembly of the surgical stapling instrument of FIG. 1 , in accordance with at least one aspect of the present disclosure.

FIG. 5 is a cross-sectional elevation view of the end effector and a portion of the shaft assembly of the surgical stapling instrument of FIG. 1 , wherein the end effector is illustrated in an unfired, clamped configuration, in accordance with at least one aspect of the present disclosure.

FIG. 6 is a plan view of the end effector and a portion of the shaft assembly of the surgical stapling instrument of FIG. 1 , in accordance with at least one aspect of the present disclosure.

FIG. 7 is a cross-sectional elevation view of the end effector and a portion of the shaft assembly of FIG. 1 taken along section line 7-7 in FIG. 6 , wherein the end effector is illustrated in an open configuration, in accordance with at least one aspect of the present disclosure.

FIG. 8 is a cross-sectional elevation view of the end effector and a portion of the shaft assembly of FIG. 1 taken along section line 8-8 in FIG. 6 , wherein the end effector is illustrated in a clamped configuration, in accordance with at least one aspect of the present disclosure.

FIG. 9 is a perspective view of a surgical stapling assembly comprising a shaft assembly and the end effector of FIG. 1 , wherein the end effector is attached to the shaft assembly by way of an articulation joint, in accordance with at least one aspect of the present disclosure.

FIG. 10 is an exploded perspective view of the surgical stapling assembly of FIG. 9 , in accordance with at least one aspect of the present disclosure.

FIG. 11 is a cross-sectional elevation view of the surgical stapling assembly of FIG. 9 , wherein the end effector is illustrated in an unfired, clamped configuration, in accordance with at least one aspect of the present disclosure.

FIG. 12 is a perspective view of a surgical stapling assembly comprising a shaft assembly and the end effector of FIG. 1 , wherein the end effector is attached to the shaft assembly by way of an articulation joint, in accordance with at least one aspect of the present disclosure.

FIG. 13 is an exploded perspective view of the surgical stapling assembly of FIG. 12 , in accordance with at least one aspect of the present disclosure.

FIG. 14 is a cross-sectional elevation view of the surgical stapling assembly of FIG. 12 , wherein the end effector is illustrated in an unfired, clamped configuration, in accordance with at least one aspect of the present disclosure.

FIG. 15 is a perspective view of a surgical stapling assembly comprising a shaft assembly and the end effector of FIG. 1 , wherein the end effector is attached to the shaft assembly by way of an articulation joint, in accordance with at least one aspect of the present disclosure.

FIG. 16 is an exploded perspective view of the surgical stapling assembly of FIG. 15 , in accordance with at least one aspect of the present disclosure.

FIG. 17 is a cross-sectional elevation view of the surgical stapling assembly of FIG. 15 , wherein the end effector is illustrated in an unfired, clamped configuration, in accordance with at least one aspect of the present disclosure.

FIG. 18 is a perspective view of a surgical end effector assembly comprising the end effector of FIG. 1 and a flexible firing drive system, in accordance with at least one aspect of the present disclosure.

FIG. 19 is an exploded perspective view of the surgical stapling assembly of FIG. 18 , in accordance with at least one aspect of the present disclosure.

FIG. 20 is a cross-sectional elevation view of the surgical end effector assembly of FIG. 18 , wherein the surgical end effector assembly is illustrated in an unfired, clamped configuration, in accordance with at least one aspect of the present disclosure.

FIG. 21 is a perspective view of robotic controller, in accordance with at least one aspect of the present disclosure.

FIG. 22 is a perspective view of a robotic arm cart for a robotic surgical system, depicting manipulators on the robotic arm cart operably supporting surgical tools, in accordance with at least one aspect of the present disclosure.

FIG. 23 is a side view of a manipulator of the surgical arm cart of FIG. 22 and a surgical grasping tool, in accordance with at least one aspect of the present disclosure.

FIG. 24 is a side elevation view of a firing member, according to various aspects of the present disclosure.

FIG. 25 is a side elevation view of the firing member of FIG. 24 in an expanded configuration, according to various aspects of the present disclosure.

FIG. 26 is an elevation cross-section view of a portion of a surgical instrument including an expandable knife portion, according to various aspects of the present disclosure.

FIG. 27 is a perspective view of a surgical instrument including an anvil having a low durometer material, depicting the surgical instrument in an open configuration, according to various aspects of the present disclosure.

FIG. 28 is an elevation cross-section view of the surgical instrument of FIG. 27 , depicting the surgical instrument in a closed configuration, according to various aspects of the present disclosure.

FIG. 29 is a perspective view of a firing member for use with a surgical instrument, according to various aspects of the present disclosure.

FIG. 30 is an enlarged view of a portion of the firing member of FIG. 29 , according to various aspects of the present disclosure.

FIG. 31 is a perspective partial cross-section view of a portion of the firing member of FIG. 29 , according to various aspects of the present disclosure.

FIG. 32 is a side elevation view of a firing member for use with a surgical instrument, depicting the firing member in a first configuration, according to various aspects of the present disclosure.

FIG. 33 is a side elevation view of the firing member of FIG. 32 in a second configuration in which the firing member is deformed from the first configuration to a loaded configuration and depicting portions of a channel and an anvil with dashed lines for environmental structure, according to various aspects of the present disclosure.

FIG. 34 is a perspective view of a firing member for use with a surgical instrument, according to various aspects of the present disclosure.

FIG. 35 is a side elevation view of the firing member of FIG. 34 , according to various aspects of the present disclosure.

FIG. 36 is a front elevation view of the firing member of FIG. 34 , according to various aspects of the present disclosure.

FIG. 37 is a graphical representation of exemplary forces imparted on the firing member of FIG. 34 during a firing stroke, according to various aspects of the present disclosure.

FIG. 38 is a perspective view of a firing member for use with a surgical instrument, according to various aspects of the present disclosure.

FIG. 39 is a side elevation view of the firing member of FIG. 38 , according to various aspects of the present disclosure.

FIG. 40 is a perspective view of a model structure before force loading shown in phantom lines and during force loading shown with solid lines, according to various aspects of the present disclosure.

FIG. 41 is an elevation view of a channel retainer having substrate portions, according to various aspects of the present disclosure.

FIG. 42 is a perspective exploded view of a portion of the substrate elements of FIG. 41 , according to various aspects of the present disclosure.

FIG. 43 is an elevation cross-section view of the channel retainer of FIG. 41 taken along the plane indicated in FIG. 41 , according to various aspects of the present disclosure.

FIG. 44 is a perspective view of a portion of a surgical instrument comprising an over-molded sleeve depicted with phantom lines, and further depicting a firing bar support within the over-molded sleeve, according to various aspects of the present disclosure.

FIG. 45 is a plan view of the portion of the surgical instrument of FIG. 44 depicted with phantom lines for the over-molded sleeve, and further depicting the instrument in an articulated configuration, according to various aspects of the present disclosure.

FIG. 46 is an elevation cross-section view of an anvil for use with a surgical instrument, according to various aspects of the present disclosure.

Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate various embodiments of the invention, in one form, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION

Applicant of the present application owns the following U.S. Patent Applications that were filed on Mar. 24, 2021 and which are each herein incorporated by reference in their respective entireties:

U.S. patent application Ser. No. 17/211,145, entitled METHOD OF USING A POWERED STAPLING DEVICE, now U.S. Patent Application Publication No. 2022/0304679;

U.S. patent application Ser. No. 17/211,161, entitled SURGICAL STAPLING ASSEMBLY COMPRISING NONPLANAR STAPLES AND PLANAR STAPLES, now U.S. Patent Application Publication No. 2022/0304684;

U.S. patent application Ser. No. 17/211,168, entitled SURGICAL STAPLE CARTRIDGE COMPRISING LONGITUDINAL SUPPORT BEAM, now U.S. Patent Application Publication No. 2022/0304685;

U.S. patent application Ser. No. 17/211,172, entitled ROTARY-DRIVEN SURGICAL STAPLING ASSEMBLY COMPRISING ECCENTRICALLY DRIVEN FIRING MEMBER, now U.S. Patent Application Publication No. 2022/0304686;

U.S. patent application Ser. No. 17/211,175, entitled ROTARY-DRIVEN SURGICAL STAPLING ASSEMBLY COMPRISING A FLOATABLE COMPONENT, now U.S. Patent Application Publication No. 2022/0304687;

U.S. patent application Ser. No. 17/211,182, entitled DRIVERS FOR FASTENER CARTRIDGE ASSEMBLIES HAVING ROTARY DRIVE SCREWS, now U.S. Patent Application Publication No. 2022/0304680;

U.S. patent application Ser. No. 17/211,189, entitled MATING FEATURES BETWEEN DRIVERS AND UNDERSIDE OF A CARTRIDGE DECK, now U.S. Patent Application Publication No. 2022/0304681;

U.S. patent application Ser. No. 17/211,192 entitled LEVERAGING SURFACES FOR CARTRIDGE INSTALLATION, now U.S. Patent Application Publication No. 2022/0304690;

U.S. patent application Ser. No. 17,211,197, entitled FASTENER CARTRIDGE WITH NON-REPEATING FASTENER ROWS, now U.S. Patent Application Publication No. 2022/0304682;

U.S. patent application Ser. No. 17/211,207, entitled FIRING MEMBERS HAVING FLEXIBLE PORTIONS FOR ADAPTING TO A LOAD DURING A SURGICAL FIRING STROKE, now U.S. Patent Application Publication No. 2022/0304688;

U.S. patent application Ser. No. 17/211,222, entitled MULTI-AXIS PIVOT JOINTS FOR SURGICAL INSTRUMENTS AND METHODS OF MANUFACTURING SAME, now U.S. Patent Application Publication No. 2022/0304714;

U.S. patent application Ser. No. 17/211,230, entitled JOINT ARRANGEMENTS FOR MULTI-PLANAR ALIGNMENT AND SUPPORT OF OPERATIONAL DRIVE SHAFTS IN ARTICULATABLE SURGICAL INSTRUMENTS, now U.S. Patent Application Publication No. 2022/0304715; and

U.S. patent application Ser. No. 17/211,242, entitled SURGICAL INSTRUMENT ARTICULATION JOINT ARRANGEMENTS COMPRISING MULTIPLE MOVING LINKAGE FEATURES, now U.S. Patent Application Publication No. 2022/0304683.

Applicant of the present application owns the following U.S. Patent Applications and U.S. Patents that were filed on Dec. 19, 2017 and which are each herein incorporated by reference in their respective entireties:

U.S. Pat. No. 10,835,330, entitled METHOD FOR DETERMINING THE POSITION OF A ROTATABLE JAW OF A SURGICAL INSTRUMENT ATTACHMENT ASSEMBLY;

U.S. Pat. No. 10,716,565, entitled SURGICAL INSTRUMENTS WITH DUAL ARTICULATION DRIVES;

U.S. patent application Ser. No. 15/847,325, entitled SURGICAL TOOLS CONFIGURED FOR INTERCHANGEABLE USE WITH DIFFERENT CONTROLLER INTERFACES, now U.S. Patent Application Publication No. 2019/0183491;

U.S. Pat. No. 10,729,509 entitled SURGICAL INSTRUMENT COMPRISING CLOSURE AND FIRING LOCKING MECHANISM;

U.S. patent application Ser. No. 15/847,315, entitled ROBOTIC ATTACHMENT COMPRISING EXTERIOR DRIVE ACTUATOR, now U.S. Patent Application Publication No. 2019/0183594; and

U.S. Design Pat. No. D910,847, entitled SURGICAL INSTRUMENT ASSEMBLY.

Applicant of the present application owns the following U.S. Patent Applications and U.S. Patents that were filed on Jun. 28, 2017 and which are each herein incorporated by reference in their respective entireties:

U.S. patent application Ser. No. 15/635,693, entitled SURGICAL INSTRUMENT COMPRISING AN OFFSET ARTICULATION JOINT, now U.S. Patent Application Publication No. 2019/0000466;

U.S. patent application Ser. No. 15/635,729, entitled SURGICAL INSTRUMENT COMPRISING AN ARTICULATION SYSTEM RATIO, now U.S. Patent Application Publication No. 2019/0000467;

U.S. patent application Ser. No. 15/635,785, entitled SURGICAL INSTRUMENT COMPRISING AN ARTICULATION SYSTEM RATIO, now U.S. Patent Application Publication No. 2019/0000469;

U.S. patent application Ser. No. 15/635,808, entitled SURGICAL INSTRUMENT COMPRISING FIRING MEMBER SUPPORTS, now U.S. Patent Application Publication No. 2019/0000471;

U.S. patent application Ser. No. 15/635,837, entitled SURGICAL INSTRUMENT COMPRISING AN ARTICULATION SYSTEM LOCKABLE TO A FRAME, now U.S. Patent Application Publication No. 2019/0000472;

U.S. Pat. No. 10,779,824, entitled SURGICAL INSTRUMENT COMPRISING AN ARTICULATION SYSTEM LOCKABLE BY A CLOSURE SYSTEM;

U.S. patent application Ser. No. 15/636,029, entitled SURGICAL INSTRUMENT COMPRISING A SHAFT INCLUDING A HOUSING ARRANGEMENT, now U.S. Patent Application Publication No. 2019/0000477;

U.S. patent application Ser. No. 15/635,958, entitled SURGICAL INSTRUMENT COMPRISING SELECTIVELY ACTUATABLE ROTATABLE COUPLERS, now U.S. Patent Application Publication No. 2019/0000474;

U.S. patent application Ser. No. 15/635,981, entitled SURGICAL STAPLING INSTRUMENTS COMPRISING SHORTENED STAPLE CARTRIDGE NOSES, now U.S. Patent Application Publication No. 2019/0000475;

U.S. patent application Ser. No. 15/636,009, entitled SURGICAL INSTRUMENT COMPRISING A SHAFT INCLUDING A CLOSURE TUBE PROFILE, now U.S. Patent Application Publication No. 2019/0000476;

U.S. Pat. No. 10,765,427, entitled METHOD FOR ARTICULATING A SURGICAL INSTRUMENT;

U.S. patent application Ser. No. 15/635,530, entitled SURGICAL INSTRUMENTS WITH ARTICULATABLE END EFFECTOR WITH AXIALLY SHORTENED ARTICULATION JOINT CONFIGURATIONS, now U.S. Patent Application Publication No. 2019/0000457;

U.S. Pat. No. 10,588,633, entitled SURGICAL INSTRUMENTS WITH OPEN AND CLOSABLE JAWS AND AXIALLY MOVABLE FIRING MEMBER THAT IS INITIALLY PARKED IN CLOSE PROXIMITY TO THE JAWS PRIOR TO FIRING;

U.S. patent application Ser. No. 15/635,559, entitled SURGICAL INSTRUMENTS WITH JAWS CONSTRAINED TO PIVOT ABOUT AN AXIS UPON CONTACT WITH A CLOSURE MEMBER THAT IS PARKED IN CLOSE PROXIMITY TO THE PIVOT AXIS, now U.S. Patent Application Publication No. 2019/0000459;

U.S. Pat. No. 10,786,253, entitled SURGICAL END EFFECTORS WITH IMPROVED JAW APERTURE ARRANGEMENTS;

U.S. patent application Ser. No. 15/635,594, entitled SURGICAL CUTTING AND FASTENING DEVICES WITH PIVOTABLE ANVIL WITH A TISSUE LOCATING ARRANGEMENT IN CLOSE PROXIMITY TO AN ANVIL PIVOT AXIS, now U.S. Patent Application Publication No. 2019/0000461;

U.S. patent application Ser. No. 15/635,612, entitled JAW RETAINER ARRANGEMENT FOR RETAINING A PIVOTABLE SURGICAL INSTRUMENT JAW IN PIVOTABLE RETAINING ENGAGEMENT WITH A SECOND SURGICAL INSTRUMENT JAW, now U.S. Patent Application Publication No. 2019/0000462;

U.S. Pat. No. 10,758,232, entitled SURGICAL INSTRUMENT WITH POSITIVE JAW OPENING FEATURES;

U.S. Pat. No. 10,639,037, entitled SURGICAL INSTRUMENT WITH AXIALLY MOVABLE CLOSURE MEMBER;

U.S. Pat. No. 10,695,057, entitled SURGICAL INSTRUMENT LOCKOUT ARRANGEMENT;

U.S. Design Pat. No. D851,762, entitled ANVIL;

U.S. Design Pat. No. D854,151, entitled SURGICAL INSTRUMENT SHAFT; and

U.S. Design Pat. No. D869,655, entitled SURGICAL FASTENER CARTRIDGE.

Applicant of the present application owns the following U.S. Patent Applications and U.S. Patents that were filed on Jun. 27, 2017 and which are each herein incorporated by reference in their respective entireties:

U.S. patent application Ser. No. 15/634,024, entitled SURGICAL ANVIL MANUFACTURING METHODS, now U.S. Patent Application Publication No. 2018/0368839;

U.S. Pat. No. 10,772,629, entitled SURGICAL ANVIL ARRANGEMENTS;

U.S. patent application Ser. No. 15/634,046, entitled SURGICAL ANVIL ARRANGEMENTS, now U.S. Patent Application Publication No. 2018/0368841;

U.S. Pat. No. 10,856,869, entitled SURGICAL ANVIL ARRANGEMENTS;

U.S. patent application Ser. No. 15/634,068, entitled SURGICAL FIRING MEMBER ARRANGEMENTS, now U.S. Patent Application Publication No. 2018/0368843;

U.S. patent application Ser. No. 15/634,076, entitled STAPLE FORMING POCKET ARRANGEMENTS, now U.S. Patent Application Publication No. 2018/0368844;

U.S. patent application Ser. No. 15/634,090, entitled STAPLE FORMING POCKET ARRANGEMENTS, now U.S. Patent Application Publication No. 2018/0368845;

U.S. patent application Ser. No. 15/634,099, entitled SURGICAL END EFFECTORS AND ANVILS, now U.S. Patent Application Publication No. 2018/0368846; and

U.S. Pat. No. 10,631,859, entitled ARTICULATION SYSTEMS FOR SURGICAL INSTRUMENTS.

Applicant of the present application owns the following U.S. Patent Applications that were filed on Jun. 2, 2020 and which are each herein incorporated by reference in their respective entireties:

U.S. Design patent application Ser. No. 29/736,648, entitled STAPLE CARTRIDGE;

U.S. Design patent application Ser. No. 29/736,649, entitled STAPLE CARTRIDGE;

U.S. Design patent application Ser. No. 29/736,651, entitled STAPLE CARTRIDGE;

U.S. Design patent application Ser. No. 29/736,652, entitled STAPLE CARTRIDGE;

U.S. Design patent application Ser. No. 29/736,653, entitled STAPLE CARTRIDGE;

U.S. Design patent application Ser. No. 29/736,654, entitled STAPLE CARTRIDGE; and

U.S. Design patent application Ser. No. 29/736,655, entitled STAPLE CARTRIDGE.

Applicant of the present application owns the following U.S. Design Patent Applications and U.S. Patents that were filed on Nov. 14, 2016, and which are each herein incorporated by reference in their respective entireties:

U.S. patent application Ser. No. 15/350,621, now U.S. Patent Application Publication No. 2018/0132849, entitled STAPLE FORMING POCKET CONFIGURATIONS FOR CIRCULAR STAPLER ANVIL;

U.S. patent application Ser. No. 15/350,624, now U.S. Patent Application Publication No. 2018/0132854, entitled CIRCULAR SURGICAL STAPLER WITH ANGULARLY ASYMMETRIC DECK FEATURES;

U.S. Design Pat. No. D833,608, titled STAPLING HEAD FEATURE FOR SURGICAL STAPLER; and

U.S. Design Pat. No. D830,550, titled SURGICAL STAPLER.

Numerous specific details are set forth to provide a thorough understanding of the overall structure, function, manufacture, and use of the embodiments as described in the specification and illustrated in the accompanying drawings. Well-known operations, components, and elements have not been described in detail so as not to obscure the embodiments described in the specification. The reader will understand that the embodiments described and illustrated herein are non-limiting examples, and thus it can be appreciated that the specific structural and functional details disclosed herein may be representative and illustrative. Variations and changes thereto may be made without departing from the scope of the claims.

The terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”) and “contain” (and any form of contain, such as “contains” and “containing”) are open-ended linking verbs. As a result, a surgical system, device, or apparatus that “comprises,” “has,” “includes” or “contains” one or more elements possesses those one or more elements, but is not limited to possessing only those one or more elements. Likewise, an element of a system, device, or apparatus that “comprises,” “has,” “includes” or “contains” one or more features possesses those one or more features, but is not limited to possessing only those one or more features.

The terms “proximal” and “distal” are used herein with reference to a clinician manipulating the handle portion of the surgical device. The term “proximal” refers to the portion closest to the clinician and the term “distal” refers to the portion located away from the clinician. It will be further appreciated that, for convenience and clarity, spatial terms such as “vertical”, “horizontal”, “up”, and “down” may be used herein with respect to the drawings. However, surgical device are used in many orientations and positions, and these terms are not intended to be limiting and/or absolute. In the following description, terms such as “first,” “second,” “top,” “bottom,” “up,” “down,” and the like are words of convenience and are not to be construed as limiting terms.

References to items in the singular should be understood to include items in the plural, and vice versa, unless explicitly stated otherwise or clear from the text. Grammatical conjunctions are intended to express any and all disjunctive and conjunctive combinations of conjoined clauses, sentences, words, and the like, unless otherwise stated or clear from the context. Thus, the term “or” should generally be understood to mean “and/or”, etc.

Recitation of ranges of values herein are not intended to be limiting, referring instead individually to any and all values falling within the range, unless otherwise indicated herein, and each separate value within such a range is incorporated into the disclosure as if it were individually recited herein. The words “about,” “approximately” or the like, when accompanying a numerical value, are to be construed as indicating a deviation as would be appreciated by one of ordinary skill in the art to operate satisfactorily for an intended purpose. Similarly, words of approximation such as “approximately” or “substantially” when used in reference to physical characteristics, should be construed to contemplate a range of deviations that would be appreciated by one of ordinary skill in the art to operate satisfactorily for a corresponding use, function, purpose or the like.

The use of any and all examples, or exemplary language (“e.g.,” “such as,” or the like) provided herein, is intended merely to better illuminate the embodiments and does not pose a limitation on the scope of the embodiments. No language in the specification should be construed as indicating any unclaimed element as essential to the practice of the embodiments.

Various exemplary devices and methods are provided for performing laparoscopic and minimally invasive surgical procedures. However, the reader will readily appreciate that the various methods and devices disclosed herein can be used in numerous surgical procedures and applications including, for example, in connection with open surgical procedures. As the present Detailed Description proceeds, the reader will further appreciate that the various surgical devices disclosed herein can be inserted into a body in any way, such as through a natural orifice, through an incision or puncture hole formed in tissue, etc. The working portions or end effector portions of the surgical devices can be inserted directly into a patient's body or can be inserted through an access device that has a working channel through which the end effector and elongate shaft of a surgical device can be advanced.

A surgical stapling system can comprise a shaft and an end effector extending from the shaft. The end effector comprises a first jaw and a second jaw. The first jaw comprises a staple cartridge. The staple cartridge is insertable into and removable from the first jaw; however, other embodiments are envisioned in which a staple cartridge is not removable from, or at least readily replaceable from, the first jaw. The second jaw comprises an anvil configured to deform staples ejected from the staple cartridge. The second jaw is pivotable relative to the first jaw about a closure axis; however, other embodiments are envisioned in which the first jaw is pivotable relative to the second jaw. The surgical stapling system further comprises an articulation joint configured to permit the end effector to be rotated, or articulated, relative to the shaft. The end effector is rotatable about an articulation axis extending through the articulation joint. Other embodiments are envisioned which do not include an articulation joint.

The staple cartridge comprises a cartridge body. The cartridge body includes a proximal end, a distal end, and a deck extending between the proximal end and the distal end. In use, the staple cartridge is positioned on a first side of the tissue to be stapled and the anvil is positioned on a second side of the tissue to be stapled. The anvil is moved toward the staple cartridge to compress and clamp the tissue against the deck. Thereafter, staples removably stored in the cartridge body can be deployed into the tissue. The cartridge body includes staple cavities defined therein wherein staples are removably stored in the staple cavities. The staple cavities are arranged in six longitudinal rows. Three rows of staple cavities are positioned on a first side of a longitudinal slot and three rows of staple cavities are positioned on a second side of the longitudinal slot. Other arrangements of staple cavities and staples are contemplated.

The staples are supported by staple drivers in the cartridge body. The drivers are movable between a first, or unfired, position and a second, or fired, position to eject the staples from the staple cavities. The drivers are retained in the cartridge body by a retainer which extends around the bottom of the cartridge body and includes resilient members configured to grip the cartridge body and hold the retainer to the cartridge body. The drivers are movable between their unfired positions and their fired positions by a sled. The sled is movable between a proximal position adjacent a proximal end of the cartridge body and a distal position adjacent a distal end of the cartridge body. The sled comprises a plurality of ramped surfaces configured to slide under the drivers and lift the drivers, and the staples supported thereon, toward the anvil.

Further to the above, the sled is moved distally by a firing member. The firing member is configured to contact the sled and push the sled toward the distal end. The longitudinal slot defined in the cartridge body is configured to receive the firing member. The anvil also includes a slot configured to receive the firing member. The firing member further comprises a first cam which engages the first jaw and a second cam which engages the second jaw. As the firing member is advanced distally, the first cam and the second cam can control the distance, or tissue gap, between the deck of the staple cartridge and the anvil. The firing member also comprises a knife configured to incise the tissue captured intermediate the staple cartridge and the anvil. It is desirable for the knife to be positioned at least partially proximal to the ramped surfaces such that the staples are ejected into the tissue ahead of the knife transecting the tissue.

FIGS. 1-8 depict a surgical stapling instrument 10 configured to clamp, staple, and cut tissue of a patient. The surgical stapling instrument 10 comprises a handle 20, a shaft assembly 100 attached to the handle 20, and an end effector 200. To cut and staple tissue of a patient, the end effector 200 comprises a cartridge jaw 201 and an anvil jaw 203. The anvil jaw 203 is pivotable relative to the cartridge jaw 203 to clamp tissue between the anvil jaw 203 and the cartridge jaw 203. Once tissue is clamped between the jaws 201, 203, the surgical stapling instrument 10 may be actuated to advance a firing member through the jaws 201, 203 to staple and cut tissue with the end effector 200 as discussed in greater detail below.

Discussed in greater detail below, the end effector 200 is articulatable by way of an articulation region 110 of the shaft assembly 100. Such articulation provides a user of the surgical stapling instrument 10 with the ability to position and/or maneuver the end effector 200 near the target tissue more accurately.

The handle 20 comprises a housing 21 configured to house various mechanical and electrical components and a handle portion 22 extending from the housing 21. The handle portion 22 is configured to fit in the palm of a user and/or be gripped and/or held by a user using the surgical stapling instrument 10. The handle 20 further comprises various actuators and/or triggers configured to be actuated by a user to operate one or more functions of the surgical stapling instrument 10. The handle 20 comprises a closure trigger 24, a firing trigger 25, and at least one articulation actuator 26. When actuated by a user, the closure trigger 24 is configured to clamp tissue with the end effector 200 by moving the anvil jaw 203 toward the cartridge jaw 201. When actuated by a user, the firing trigger 25 is configured to cut and staple tissue with the end effector 200 by advancing a firing member to eject staples and cut tissue with a knife. When actuated by a user, the articulation actuator 26 is configured to articulate the end effector 200 relative to the shaft assembly 100 by way of the articulation region 110. The triggers and actuators of the surgical stapling instrument 10 can either trigger one or more motors within the handle 20 to actuate various function of the surgical stapling instrument 10 and/or manually drive various drive shafts and components to actuate various function of the surgical stapling instrument 10.

The handle 20 further comprises a nozzle assembly 30 configured to support the shaft assembly 100 therein. The nozzle assembly 30 comprises an actuation wheel 31 configured to be rotated by a user to rotate the shaft assembly 100 and end effector 200 about a longitudinal axis LA relative to the handle 20. Such a mechanism permits the user of the surgical stapling instrument 10 to rotate only the shaft assembly 100 and/or end effector 200 without having to rotate the entire handle 20.

The handle 20 further comprises a battery 23 configured to provide power to various electronic components, sensors, and/or motors of the surgical stapling instrument 10. Embodiments are envisioned where the surgical stapling instrument 10 is directly connected to a power source. Embodiments are also envisioned where the surgical stapling instrument 10 is entirely manual or, non-powered, for example. Embodiments are further envisioned where articulation of the end effector, clamping and unclamping of the jaws, firing of the end effector staple and cut tissue, and shaft and/or end effector rotation are all powered systems.

In at least one instance, the shaft assembly 100 and the end effector 200 may be modular and removable from the handle 20. In at least one instance, the end effector 200 may be modular in that the end effector 200 can be removed from the shaft assembly 100 and replaced with a different end effector. In at least one instance, the shaft assembly 100 and/or the end effector 200 is employable in a surgical robotic environment. Such an embodiment would provide powered inputs from a surgical robotic interface to actuate each function of the end effector 200. Examples of such surgical robots and surgical tools are further described in U.S. Patent Application Publication No. 2020/0138534, titled ROBOTIC SURGICAL SYSTEM, which published on May 7, 2020, which is incorporated by reference herein in its entirety.

In at least one instance, the shaft assembly 100 and the end effector 200 are configured to be used with a surgical robot. In such an instance, the shaft assembly 100 and the end effector 200 are configured to be coupled to a surgical robot comprising a plurality of output drives. The plurality of output drives of the surgical robot are configured to mate with the drive systems of the shaft assembly 100 and end effector 200. In such an instance, the surgical robot can actuate the various different functions of the end effector 200 such as, for example, articulating the end effector about multiple different articulation joints, rotating the shaft assembly 100 and/or end effector 200 about its longitudinal axis, clamping the end effector 200 to clamp tissue between the jaws of the end effector 200, and/or firing the end effector 200 to cut and/or staple tissue.

The shaft assembly 100 is configured to house various drive system components and/or electronic components of the surgical stapling instrument 10 so that the end effector 200 and shaft assembly 100 may be inserted through a trocar for laparoscopic surgery. The various drive system components are configured to be actuated by the various triggers and actuators of the handle 20. Such components can include drive shafts for articulation, drive shafts for clamping and unclamping the end effector 200, and/or drive shafts for firing the end effector 200. Such drive shafts may be rotated by a drive system in the handle 20 or a surgical robotic interface in the instance where the shaft assembly 100 is connected to the same. In various aspects, a stapling end effector can include two independently rotatable drive members—one for grasping tissue and one for firing staples, for example. The stapling end effector can further include an articulation joint, and the rotary motions can be transmitted through the articulation joint. In various aspects, the stapling end effector can include one or more 3D printed assemblies, which can be incorporated into an articulation, grasping, or firing systems.

Such drive shafts may be actuated by a drive system in the handle 20 or a surgical robotic interface in the instance where the shaft assembly 100 is connected to the same. Such drive shafts may comprise linear actuation, rotary actuation, or a combination thereof. A combination of rotary actuation and linear actuation may employ a series of rack gears and/or drive screws, for example.

In at least one instance, the shaft assembly 100 is also configured to house electrical leads for various sensors and/or motors, for example, positioned within the shaft assembly 100 and/or end effector 200, for example.

The shaft assembly 100 comprises an outer shaft 101 extending from the nozzle assembly 30 to the articulation region 110 comprising dual articulation joints, discussed in greater detail below. The articulation region 110 allows the end effector 200 to be articulated relative to the outer shaft 101 in two distinct planes about two separate axes AA1, AA2.

Referring now primarily to FIG. 4 , articulation of the end effector 200 will now be described. The articulation region 110 comprises two distinct articulation joints and two articulation actuators 150, 160. This allows the end effector 200 to be articulated in two different planes about two different axes AA1, AA2 independently of each other. The articulation region 110 comprises a proximal joint shaft component 120, an intermediate joint shaft component 130, and a distal joint shaft component 140. The proximal joint shaft component 120 is attached to a distal end of the shaft assembly 100, the intermediate joint shaft component 130 is pivotally connected to the proximal joint shaft component 120 and the distal joint shaft component 140, and the distal joint shaft component 140 is fixedly attached to the end effector 200 by way of a retention ring 146. Discussed in greater detail below, this arrangement provides articulation of the end effector 200 relative to the shaft assembly 100 about axis AA1 and axis AA2 independently of each other.

The proximal joint shaft component 120 comprises a proximal annular portion 121 fixedly fitted within the outer shaft 101. The proximal joint shaft component 120 also includes a hollow passage 122 to allow various drive system components to pass therethrough, and further includes an articulation tab 123 comprising a pin hole 124 configured to receive articulation pin 125. The articulation pin 125 pivotally connects the proximal joint shaft component 120 to a proximal articulation tab 131 of the intermediate joint shaft component 130. To articulate the end effector 200 about axis AA1, the articulation actuator 150 is actuated linearly either in a distal direction or a proximal direction. Such an actuator may comprise a bar or rod made of any suitable material such as metal and/or plastic, for example. The articulation actuator 150 is pivotally mounted to an articulation crosslink 151. The articulation crosslink 151 is pivotally mounted to the intermediate joint shaft component 130 off-axis relative to the articulation pin 125 so that when the articulation actuator 150 is actuated, a torque is applied to the intermediate joint shaft component 130 off-axis relative to the articulation pin 125 by the articulation crosslink 151 to cause the intermediate joint shaft component 130 and, thus, the end effector 200, to pivot about axis AA1 relative to the proximal joint shaft component 120.

The intermediate joint shaft component 130 is pivotally connected to the proximal joint shaft component 120 by way of the articulation pin 125 which defines axis AA1. Specifically, the intermediate joint shaft component 130 comprises a proximal articulation tab 131 that is pivotally connected to the proximal joint shaft component 120 by way of the articulation pin 125. The intermediate joint shaft component 130 further comprises a hollow passage 132 configured to allow various drive system components to pass therethrough and a distal articulation tab 133. The distal articulation tab 133 comprises a pin hole 134 configured to receive another articulation pin 136, which defines axis AA2, and a distally-protruding key 135.

To articulate the end effector 200 about axis AA2, the articulation cable 160 is actuated to apply an articulation torque to a proximal tab 141 of the distal joint shaft component 140 by way of the key 135. The articulation cable 160 is fixed to the key 135 such that, as the cable 160 is rotated, the key 135 is pivoted relative to the intermediate joint shaft component 130. The key 135 is fitted within a key hole 144 of the distal joint shaft component 140. Notably, the key 135 is not fixed to the intermediate joint shaft component 130 and the key 135 can be rotated relative to the intermediate joint shaft component 130. The articulation cable 160 also contacts the proximal tab 141 around the pin hole 142. This provides an additional torque moment from the articulation cable 160 to the distal joint shaft component 140. The articulation pin 136 is received within the pin hole 142 to pivotally couple the intermediate joint shaft component 130 and the distal joint shaft component 140.

In at least one instance, the articulation cable 160 is only able to be pulled in a proximal direction. In such an instance, only one side of the articulation cable 160 would be pulled proximally to articulate the end effector 200 in the desired direction. In at least one instance, the articulation cable 160 is pushed and pulled antagonistically. In other words, the cable 160 can comprise a rigid construction such that one side of the articulation cable 160 is pushed distally while the other side of the articulation cable 160 is pulled proximally. Such an arrangement can allow the articulation forces to be divided between the pushed half of the cable 160 and the pulled half of the cable 160. In at least one instance, the push-pull arrangement allows greater articulation forces to be transmitted to the corresponding articulation joint. Such forces may be necessary in an arrangement with two articulation joints. For example, if the proximal articulation joint is fully articulated, more force may be required of the articulation actuator meant to articulate the distal articulation joint owing to the stretching and/or lengthened distance that the articulation actuator for the distal articulation joint must travel.

The distal joint shaft component 140 further comprises a cutout 143 to allow various drive components to pass therethrough. The retention ring 146 secures a channel 210 of the cartridge jaw 201 to the distal joint shaft component 140 thereby fixing the end effector assembly 200 to a distal end of the articulation region 110.

As discussed above, the anvil jaw 201 is movable relative to the cartridge jaw 203 to clamp and unclamp tissue with the end effector 200. Operation of this function of the end effector 200 will now be described. The cartridge jaw 201 comprises the channel 210 and a staple cartridge 220 configured to be received within a cavity 214 of the channel 210. The channel 210 further comprises an annular groove 211 configured to receive the retention ring 146 and a pair of pivot holes 213 configured to receive a jaw-coupling pin 233. The jaw coupling pin 233 permits the anvil jaw 203 to be pivoted relative to the cartridge jaw 201.

The anvil jaw 203 comprises an anvil body 230 and a pair of pivot holes 231. The pivot holes 231 in the proximal portion of the anvil jaw 203 are configured to receive the jaw-coupling pin 233 thereby pivotally coupling the anvil jaw 203 to the cartridge jaw 201. To open and close the anvil jaw 203 relative to the cartridge jaw 201, a closure drive 250 is provided.

The closure drive 250 is actuated by a flexible drive segment 175 comprised of universally-movable joints arranged or formed end-to-end. In various instances, the flexible drive segment 175 can includes serial 3D-printed universal joints, which are printed all together as a single continuous system. Discussed in greater detail below, the flexible drive segment 175 is driven by an input shaft traversing through the shaft assembly 100. The flexible drive segment 175 transmits rotary actuation motions through the dual articulation joints. The closure drive 250 comprises a closure screw 251 and a closure wedge 255 threadably coupled to the closure screw 251. The closure wedge 255 is configured to positively cam the anvil jaw 203 open and closed. The closure screw 251 is supported by a first support body 258 and a second support body 259 secured within the channel 210.

To move the anvil jaw 203 between a clamped position (FIG. 8 ) and an unclamped position (FIG. 7 ), a closure drive shaft is actuated to actuate the flexible drive segment 175. The flexible drive segment 175 is configured to rotate the closure screw 251, which displaces the closure wedge 255. For example, the closure wedge 255 is threadably coupled to the closure screw 251 and rotational travel of the closure wedge 255 with the staple cartridge 220 is restrained. The closure screw 251 drives the closure wedge 255 proximally or distally depending on which direction the closure screw 251 is rotated.

To clamp the end effector 200 from an unclamped position (FIG. 7 ), the closure wedge 255 is moved proximally. As the closure wedge 255 is moved proximally, a proximal cam surface 256 of the closure wedge 255 contacts a corresponding cam surface 234 defined in a proximal end 235 of the anvil body 230. As the cam surface 256 contacts the cam surface 234, a force is applied to the proximal end 235 of the anvil body 230 causing the anvil body 230 to rotate into the clamped position (FIG. 8 ) about the pin 233.

To open or unclamp the end effector 200 from a clamped position (FIG. 8 ), the closure wedge 255 is moved distally by rotating the closure screw 251 in a direction opposite to the direction that causes the closure wedge 255 to move proximally. As the closure wedge 255 is moved distally, a pair of nubs 257 extending from a distal end of the closure wedge 255 contact the cam surface 234 near a downwardly extending tab 237 of the anvil body 230. As the nubs 257 contact the cam surface 234 near the tab 237, a force is applied to the anvil body 230 to rotate the anvil body 230 into the open position (FIG. 7 ) about the pin 233.

In at least one instance, the profile of the cam surface 234 corresponds to the profile of the cam surface 256. For example, the cam surface 234 and the cam surface 256 may match such that a maximum cam force is applied to the anvil body 230 to cause the desired rotation of the anvil body 230. As can be seen in FIG. 8 , for example, the cam surface 234 defined by the proximal end 235 of the anvil body 230 comprises a ramped section similar to that of the upper ramped section of the cam surface 256.

As discussed above, the surgical stapling instrument 10 may be actuated to advance a firing member through the jaws 201, 203 to staple and cut tissue with the end effector 200. The function of deploying staples 226 from the staple cartridge 220 and cutting tissue with knife 283 will now be described. The staple cartridge 220 comprises a cartridge body 221, a plurality of staple drivers 225, and a plurality of staples 226 removably stored within the cartridge body 221. The cartridge body 221 comprises a deck surface 222, a plurality of staple cavities 223 arranged in longitudinal rows defined in the cartridge body 221, and a longitudinal slot 224 bifurcating the cartridge body 221. The knife 283 is configured to be driven through the longitudinal slot 224 to cut tissue clamped between the anvil body 230 and the deck surface 221.

The deck surface 221 comprises a laterally-contoured tissue-supporting surface. In various aspects, the contour of the deck surface 221 can form a peak along a central portion of the cartridge body 221. Such a peak can overlay a longitudinally-extending firing screw 261 that extends through the central portion of the cartridge body 221, which is further described herein. The increased height along the peak can be associated with a smaller tissue gap along a firing path of the knife 283 in various instances. In certain aspects of the present disclosure, driver heights, formed staple heights, staple pocket extension heights, and/or staple overdrive distances can also vary laterally along the deck surface 221. Laterally-variable staple formation (e.g. a combination of 2D staples and 3D staples) is also contemplated and further described herein.

The staple drivers 225 are configured to be lifted by a sled 280 as the sled 280 is pushed distally through the staple cartridge 220 to eject the staples 226 supported by the staple drivers 225 in the staple cavities 223. The sled 280 comprises ramps 281 to contact the staple drivers 225. The sled 280 also includes the knife 283. The sled 280 is configured to be pushed by a firing member 270.

To deploy the staples 226 and cut tissue with the knife 283, the end effector 200 comprises a firing drive 260. The firing drive 260 is actuated by a flexible drive shaft 176. Discussed in greater detail below, the flexible drive shaft 176 is driven by an input shaft traversing through the shaft assembly 100. The flexible drive shaft 176 transmits rotary actuation motions through the dual articulation joints. The firing drive 260 comprises a firing screw 261 configured to be rotated by the flexible drive shaft 176. The firing screw 261 comprises journals supported within bearings in the support member 259 and the channel 210. In various instances, the firing screw 261 can float relative to the channel 210, as further described herein. The firing screw 261 comprises a proximal end 262 supported within the support member 259 and the channel 210, a distal end 263 supported within the channel 210, and threads 265 extending along a portion of the length of the firing screw 261.

The firing member 270 is threadably coupled to the firing screw 261 such that as the firing screw 261 is rotated, the firing member 270 is advanced distally or retracted proximally along the firing screw 261. Specifically, the firing member 270 comprises a body portion 271 comprising a hollow passage 272 defined therein. The firing screw 261 is configured to be received within the hollow passage 272 and is configured to be threadably coupled with a threaded component 273 of the firing member 270. Thus, as the firing screw 261 is rotated, the threaded component 273 applies a linear force to the body portion 271 to advance the firing member 270 distally or retract the firing member 270 proximally. As the firing member 270 is advanced distally, the firing member 270 pushes the sled 280. Distal movement of the sled 280 causes the ejection of the staples 223 by engaging the plurality of staple drivers 225, as further described herein. The driver 225 is a triple driver, which is configured to simultaneously fire multiple staples 223. The driver 225 can comprise lateral asymmetries, as further described herein, to maximum the width of the sled rails and accommodate the firing screw 261 down the center of the cartridge 220 in various instances.

At a point during firing of the end effector 200, a user may retract the firing member 270 to allow unclamping of the jaws 201, 203. In at least one instance, the full retraction of the firing member 270 is required to open the jaws 201, 203 where upper and lower camming members are provided on the body portion 271 which can only be disengaged from the jaws 201, 203 once the firing member 270 is fully retracted.

In various instances, the firing member 270 can be a hybrid construction of plastic and metal portions as further described herein. In various instances, the threaded component 273 can be a metal component, for example, which is incorporated into the firing member body 271 with insert molding or over molding.

The firing member 270 can also be referred to an I-beam in certain instances. The firing member 270 can include a complex 3D-printed geometry comprising a lattice pattern of spaces therein. In various instances, 3D printing can allow the firing member or a portion thereof to act as a spring and allows a portion to more readily flex, which can improve the force distribution and/or tolerances during a firing stroke, for example.

FIGS. 9-11 depict a surgical stapling assembly 300 comprising a shaft assembly 310 and the end effector 200 of FIGS. 1-8 attached to the shaft assembly 310. The shaft assembly 310 may be similar in many respects to various other shaft assemblies discussed herein; however, the shaft assembly 310 comprises a single articulation joint and an articulation bar configured to articulate the end effector 200 about the single articulation joint. The surgical stapling assembly 300 is configured to cut and staple tissue. The surgical stapling assembly 300 may be attached to a surgical instrument handle and/or surgical robotic interface. The surgical instrument handle and/or surgical robotic interface can be configured to actuate various functions of the surgical stapling assembly 300. The shaft assembly 310 comprises an articulation joint 320. Discussed in greater detail below, the end effector 200 is configured to be articulated relative to an outer shaft 311 of the shaft assembly 310 about axis AA.

The shaft assembly 310 comprises the outer shaft 311, a first shaft joint component 330, and a second shaft joint component 350 pivotally coupled to the first shaft joint component 330 by way of an articulation pin 354. The first shaft joint component 330 comprises a proximal tube portion 331 configured to fit within the inner diameter of the outer shaft 311. Such a fit may comprise a press fit, for example. However, any suitable attachment means can be used. The first shaft joint component 330 also includes a distal portion 332. The distal portion 332 comprises an articulation tab 333 comprising a pin hole 334 defined therein and a hollow passage 335 through which various drive components of the surgical stapling assembly 300 can pass. Such drive components can include articulation actuators, closure actuators, and/or firing actuators for example.

The first shaft joint component 330 is pivotally connected to the second shaft joint component 350 by way of the articulation pin 354. The articulation pin 354 is also received within a pin hole 353 of a proximally-extending articulation tab 351 of the second shaft joint component 350. The pin hole 353 is axially aligned with the pin hole 334. The articulation pin 354 allows the second shaft joint component 350 to be articulated relative to the first shaft joint component 330 about the articulation axis AA. The second shaft joint component 350 further comprises a pin protrusion 352 extending from the proximal-extending articulation tab 351. Discussed in greater detail below, the pin protrusion 352 is configured to be pivotally coupled to an articulation drive system. The second shaft joint component 350 further comprises a distal portion 355 comprising an annular groove 356 configured to receive a retention ring 358. The distal portion 355 also includes a hollow passage 357 through which various drive components of the surgical stapling assembly 300 can pass. The retention ring 358 is configured to hold the first jaw 201 to the second shaft joint component 350 by fitting within the annular groove 211 of the cartridge channel 210 and the annular groove 356 of the second shaft joint component 350.

To articulate the end effector 200 about the articulation axis AA, an articulation bar 360 is provided. The articulation bar 360 may be actuated by any suitable means such as, for example, by a robotic or motorized input and/or a manual handle trigger. The articulation bar 360 may be actuated in a proximal direction and a distal direction, for example. Embodiments are envisioned where the articulation system comprises rotary driven actuation in addition to or, in lieu of, linear actuation. The articulation bar 360 extends through the outer shaft 311. The articulation bar 360 comprises a distal end 361 pivotally coupled to an articulation link 362. The articulation link 362 is pivotally coupled to the pin protrusion 352 extending from the proximally-extending articulation tab 351 off center with respect to the articulation axis AA. Such off-center coupling of the articulation link 362 allows the articulation bar 360 to apply a force to the second joint shaft component 350 to rotate the second shaft joint component 350 and, thus, the end effector 200, relative to the first joint shaft component 330. The articulation bar 360 can be advanced distally to rotate the end effector 200 in a first direction about the articulation axis AA and retracted proximally to rotate the end effector 200 in a second direction opposite the first direction about the articulation axis AA.

The shaft assembly 310 further comprises an articulation component support structure 340 positioned within the articulation joint 320. Such a support structure can provide support to various drive components configured to pass through the articulation joint 320 to the end effector 200 as the end effector 200 is articulated. The support structure 340 may also serve to isolate the drive components from tissue remnants during use.

FIGS. 12-14 depict a surgical stapling assembly 400 comprising a shaft assembly 410 and the end effector 200 of FIGS. 1-8 attached to the shaft assembly 410. The shaft assembly 410 may be similar in many respects to various other shaft assemblies discussed herein; however, the shaft assembly 410 comprises a single articulation joint and an articulation cable configured to articulate the end effector 200 about the single articulation joint. The surgical stapling assembly 400 is configured to cut and staple tissue. The surgical stapling assembly 400 may be attached to a surgical instrument handle and/or surgical robotic interface. The surgical instrument handle and/or surgical robotic interface can be configured to actuate various functions of the surgical stapling assembly 400. The shaft assembly 410 comprises an articulation joint 420. Discussed in greater detail below, the end effector 200 is configured to be articulated relative to an outer shaft 411 of the shaft assembly 310 about an axis AA.

The shaft assembly 410 comprises the outer shaft 411, a first shaft joint component 430, and a second shaft joint component 450 pivotally coupled to the first shaft joint component 430 by way of an articulation pin 454. The first shaft joint component 430 comprises a proximal tube portion 431 configured to fit within the inner diameter of the outer shaft 411. Such a fit may comprise a press fit, for example. However, any suitable attachment means can be used. The first shaft joint component 430 also includes a distal portion 432, which comprises an articulation tab 433 comprising a pin hole 434 defined therein. The distal portion 432 further defines a hollow passage 435 through which various drive components of the surgical stapling assembly 400 can pass. Such drive components can include articulation actuators, closure actuators, and/or firing actuators, for example.

The first shaft joint component 430 is pivotally connected to the second shaft joint component 450 by way of the articulation pin 454. The articulation pin 454 is also received within a pin hole 453 of a proximally-extending articulation tab 451 of the second shaft joint component 450. The articulation pin 454 allows the second shaft joint component 450 to be articulated relative to the first shaft joint component 430 about the articulation axis AA. The second shaft joint component 450 further comprises a drive ring structure 452. The drive ring structure 452 extends from the proximally-extending articulation tab 451 and further defines a portion of the pin hole 453. Discussed in greater detail below, the drive ring structure 452 is configured to be engaged by an articulation drive system. The second shaft joint component 450 further comprises a distal portion 455 comprising an annular groove 456 configured to receive a retention ring 458. A hollow passage 457 through the distal portion 455 is configured to receive various drive components of the surgical stapling assembly 400 therethrough. The retention ring 458 is configured to hold the first jaw 201 to the second shaft joint component 450 by fitting within the annular groove 211 of the cartridge channel 210 and the annular groove 456 of the second shaft joint component 450.

To articulate the end effector 200 about the articulation axis AA, an articulation cable 460 is provided. The articulation cable 460 may be actuated by any suitable means such as, for example, by a robotic input and/or a manual trigger on a handle of a handheld surgical instrument. The articulation cable 460 may comprise an antagonistic actuation profile. In other words, as a first side of the articulation cable 460 is pulled proximally a second side of the articulation cable 460 is allowed to advance distally like a pulley system. Similarly, as the second side is pulled proximally, the first side is allowed to advance distally. The articulation cable 460 extends through the outer shaft 411. The articulation cable 460 is positioned around the drive ring structure 452 and frictionally retained thereon to permit rotation of the second shaft joint component 450 as the articulation cable 460 is actuated. As the articulation cable 460 is actuated, the articulation cable 460 is configured to apply a rotational torque to the drive ring structure 452 of the second joint shaft component 450 and, thus, the end effector 200. Such torque is configured to cause the second joint shaft component 450 to rotate, or pivot, relative to the first joint shaft component 430 thereby articulating the end effector 200 relative to the outer shaft 411. A first side of the articulation cable 460 can pulled to rotate the end effector 200 in a first direction about the articulation axis AA and a second side of the articulation cable 460 can be pulled to rotate the end effector 200 in a second direction opposite the first direction about the articulation axis AA.

The shaft assembly 410 further comprises an articulation component support structure 440 positioned within the articulation joint 420. Such a support structure 440 can provide support to various drive components configured to pass through the articulation joint 420 to the end effector 200 as the end effector 200 is articulated. The support structure 440 may also serve to isolate the drive components from tissue remnants during use.

The surgical stapling assembly 400 further comprises a closure drive shaft segment 475 and a firing drive shaft segment 476 each configured to transmit rotary motion through the articulation joint 420 to the end effector 200. The drive shaft segments 475, 476 are configured to passively expand and contract longitudinally as the end effector 200 is articulated. For example, articulation can cause expansion and contraction of the drive shaft segments 475, 476 to account for the respective longitudinal stretching of or contracting of the length of the drive shafts owing to articulation of the end effector 200 relative to the shaft assembly 410. During expansion and contraction of the drive shaft segments 475, 476, the drive shaft segments 475, 476 maintain rotary driving engagement with corresponding input shafts extending through the outer shaft 411 and output shafts in the end effector 200. In at least one instance, the output shafts comprise the closure screw 251, which is configured to effect grasping, closing, or tissue manipulation with the jaws 201, 203, and the firing screw 261, which is configured to effect clamping of the jaws 201, 203 and firing of the firing member 270.

FIGS. 15-17 depict a surgical stapling assembly 500 comprising a shaft assembly 510 and the end effector 200 of FIGS. 1-8 attached to the shaft assembly 510. The shaft assembly 510 may be similar in many respects to various other shaft assemblies discussed herein; however, the shaft assembly 510 comprises a single articulation joint and drive shaft segments configured to passively expand and contract. The surgical stapling assembly 500 is configured to cut and staple tissue. The surgical stapling assembly 500 may be attached to a surgical instrument handle and/or surgical robotic interface. The surgical instrument handle and/or surgical robotic interface can be configured to actuate various functions of the surgical stapling assembly 500. The shaft assembly 510 comprises an articulation joint 520. Discussed in greater detail below, the end effector 200 is configured to be articulated about an axis AA.

The shaft assembly 510 comprises a first shaft joint component 530 and a second shaft joint component 540 pivotally coupled to the first shaft joint component 530 by way of an articulation pin 543. The first shaft joint component 530 is configured to be attached to a shaft of a surgical instrument assembly and/or a surgical robotic interface. The first shaft joint component 530 comprises a proximal portion 531 and an articulation tab 533 comprising a pin hole 534 defined therein. In at least one instance, the first shaft joint component 530 comprises a hollow passage through which various drive components of the surgical stapling assembly 400 can pass. Such drive components can include articulation actuators, closure actuators, and/or firing actuators for example.

The first shaft joint component 530 is pivotally connected to the second shaft joint component 540 by way of the articulation pin 543. The articulation pin 543 is also received within a pin hole 542 of a proximally-extending articulation tab 541 of the second shaft joint component 540. The articulation pin 543 allows the second shaft joint component 540 to be articulated relative to the first shaft joint component 530 about the articulation axis AA. The second shaft joint component 540 further comprises a distal portion 545 comprising an annular groove 547 configured to receive a retention ring 548 and a hollow passage 546 through which various drive components of the surgical stapling assembly 500 can pass. The retention ring 548 is configured to hold the first jaw 201 to the second shaft joint component 540 by fitting within the annular groove 211 of the cartridge channel 210 and the annular groove 547 of the second shaft joint component 540.

Any suitable articulation drive system can be used to articulate the end effector 200 about axis AA. In at least one instance, the end effector 200 is passively articulated. In such an instance, the end effector 200 may be pressed against tissue, for example, to apply a force to the end effector 200 and cause the end effector 200 to articulate about an articulation axis. In at least one instance, the end effector 200 further comprises a spring configured to apply a neutral biasing force to the second shaft joint segment 540, for example, to cause the end effector 200 to be biased toward an unarticulated configuration.

The surgical stapling assembly 500 further comprises a closure drive shaft segment 575 and a firing drive shaft segment 576 each configured to transmit rotary motion through the articulation joint 520 to the end effector 200. The drive shaft segments 575, 576 are configured to passively expand and contract longitudinally as the end effector 200 is articulated. Articulation causes the drive shaft segments 575, 576 to expand and contract to account for the longitudinal stretching of or contracting of the length of the drive shafts owing to articulation of the end effector 200. During expansion and contraction of the drive shaft segments 575, 576, the drive shaft segments 575, 576 maintain rotary driving engagement with corresponding input shafts and output shafts in the end effector 200. In at least one instance, the output shafts comprise the closure screw 251 and the firing screw 261, which are further described herein.

FIGS. 18-20 depict a surgical stapling end effector assembly 600 comprising a shaft portion 610 and an end effector 600. The end effector assembly 600 is similar in many respects to various other end effector assemblies disclosed herein; however, the end effector assembly 600 comprises a multi-component firing member driven by a flexible firing shaft. The end effector assembly 600 is configured to cut and staple tissue. The end effector assembly 600 may be attached to a surgical instrument handle and/or surgical robotic interface by way of a proximal tab 611 of the shaft portion 610. The surgical instrument handle and/or surgical robotic interface can be configured to actuate various functions of the end effector assembly 600. The end effector assembly 600 comprises a cartridge channel jaw 620 and an anvil jaw 660 pivotally mounted to the cartridge channel jaw 620 to clamp tissue between the cartridge channel jaw 620 and the anvil jaw 660.

The cartridge channel jaw 620 comprises a channel 630 comprising a proximal end 631, a staple cartridge 640 configured to store a plurality of staples therein and configured to be received within the channel 630, and a support brace 650 fitted within the staple cartridge 640. The staple cartridge 640 and the support brace 650 are configured to be assembled together prior to installing the staple cartridge 640 into the channel 630. Discussed in greater detail below, the support brace 650 is configured to further support a firing member assembly as the firing member assembly is advanced through the end effector assembly 600.

The anvil jaw 660 is configured to form staples ejected from the staple cartridge 640. The anvil jaw 660 comprises a proximal end 661 comprising a pair of pin holes 662 defined therein configured to receive a coupling pin 663. The anvil jaw 660 is pivotable about the coupling pin 663 between an unclamped position and a fully clamped position. The coupling pin 663 is also received within a pair of pin holes 633 defined in the proximal end 631 of the channel 630. The coupling pin 663 serves to pivotally mount the anvil jaw 660 to the channel 630. In at least one instance, the channel 630 is mounted to the shaft portion 610 by way of a retention ring, or band, that fits around an annular groove 632 of the channel 630 and annular groove 615 of the shaft portion 610. The retention ring, or band, is configured to hold the channel 630 to the shaft portion 610.

The end effector assembly 600 comprises a closure drive 670 configured to grasp tissue between the anvil jaw 660 and the cartridge channel jaw 620 by pivoting the anvil jaw 660 relative to the channel 630. The end effector assembly 600 also includes a firing drive 680 configured to clamp, staple, and cut tissue by deploying a plurality of staples from the staple cartridge 640. The closure drive 670 comprises a closure screw 671 positioned within the channel 630 and a closure wedge 675 threadably coupled to the closure screw 671. As the closure screw 671 is rotated, the closure wedge 675 is advanced distally or retracted proximally to open or close the anvil jaw 660, respectively. The closure drive 670 may be actuated by any suitable means. For example, a rotary drive shaft may extend through the shaft portion 610 from an actuation interface, for example, to rotate the closure screw 671. Other examples of suitable rotary drive shafts are further described herein.

The firing drive 680 comprises a flexible drive shaft 681 that is configured to be moved linearly through the end effector assembly 600. The flexible drive shaft 681 may be actuated by a robotic input and/or a manually-actuated drive shaft of a handle assembly, for example. The flexible drive shaft 681 is configured to extend through a hollow passage 614 of a distal end 613 of the shaft portion 610 and is flexible so that the end effector assembly 600 may be articulated relative to a shaft from which the end effector 600 extends. The flexible drive shaft 681 extends through a clearance slot 676 defined in the closure wedge 675 and is fixedly attached to a lower firing member 682. The lower firing member 682 is configured to be reused with different staple cartridges.

The staple cartridge 640 comprises a disposable upper firing member 683 configured to hookingly engage or, latch, onto the lower firing member 682 such that the lower firing member 582 can push or, drive, the upper firing member 683 through the staple cartridge 640 and support brace 650. In other words, the firing actuation involves a two-part firing member—a disposable upper firing member 683 incorporated into the cartridge 640 and a reusable lower firing member 682 incorporated into the firing drive 680, which can be coupled together when the cartridge 640 is seated in the elongate channel 630. The two-part firing member is further described herein.

The upper firing member 683 comprises an upper flange configured to engage and position the anvil jaw 660, a knife edge configured to cut tissue, and a latch portion configured to hookingly engage the lower firing member 682. The staple cartridge 640 further comprises a sled 684 configured to engage staple drivers positioned within the staple cartridge 640 to eject staples from the staple cartridge 640. Because a knife and cutting edge are incorporated into the disposable upper firing member 683 of the staple cartridge 640, a new and/or fresh cutting edge can be supplied with each staple cartridge loaded into the end effector assembly 600.

The lower firing member 682 and the upper firing member 683 are configured to move through the support brace 650 such that the vertical loads associated with the firing sequence are configured to be distributed through the support brace 650, the staple cartridge 640, the channel 630, and the anvil jaw 660. The support brace 650 may be comprised of a metal material, for example, to be inserted within the staple cartridge 640. The support brace 650 comprises key rails 655 configured to fit within corresponding key slots defined in a longitudinal slot of the staple cartridge 640. The support brace 650 further comprises a longitudinal slot 653 configured to receive the knife of the upper firing member 683, a cylindrical passage 657 configured to receive a portion of the upper firing member 683, a portion of the lower firing member 682, and the flexible drive shaft 681. The support brace 650 further comprises vertical key extensions 656 configured to be received within corresponding key holes in the cartridge deck. Such extensions may be visible through the cartridge deck when the support brace 650 is installed within the staple cartridge 640. In at least one instance, the support brace 650 is configured to be inserted into the staple cartridge 640 from the bottom of the staple cartridge 640 facing the channel 630.

The support brace 650 further comprises a proximal tab 651 and a distal tab 653, which are both configured to be engaged with the channel 630. The tabs 651, 653 are configured to distribute at least some of the forces transmitted through the assembly 600 by the firing drive 680 and corresponding components. The distal tab 651 may serve to block the upper and lower firing members 683, 682 from being pushed through a distal end of the support brace 650 by sharing and/or redistributing the load applied to the support brace 650 by the firing drive 680 with the channel 630.

When the staple cartridge 640 is replaced so that the end effector assembly 600 can be reused, the staple cartridge 640 is removed from the channel jaw 630. Removing the staple cartridge 640 from the channel jaw 630 removes the upper firing member 683, the sled 684, the support brace 650, and the staple cartridge 640. A fresh knife can be provided with a replacement staple cartridge.

Various embodiments disclosed herein may be employed in connection with a robotic system 700. An exemplary robotic system is depicted in FIGS. 21-23 , for example. FIG. 21 depicts a master controller 701 that may be used in connection with a surgical robot, such as the robotic arm slave cart 800 depicted in FIG. 22 , for example. Master controller 701 and robotic arm slave cart 800, as well as their respective components and control systems are collectively referred to herein as a robotic system 700. Examples of such systems and devices are disclosed in U.S. Pat. No. 7,524,320, entitled MECHANICAL ACTUATOR INTERFACE SYSTEM FOR ROBOTIC SURGICAL TOOLS, as well as U.S. Pat. No. 9,072,535, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, which are each hereby incorporated by reference herein in their respective entireties. As is known, the master controller 701 generally includes controllers (generally represented as 703 in FIG. 21 ) which are grasped by the surgeon and manipulated in space while the surgeon views the procedure via a stereo display 702. The controllers 701 generally comprise manual input devices which preferably move with multiple degrees of freedom, and which often further have an actuatable handle, trigger, or actuator for actuating tools (for example, for closing grasping jaws, applying an electrical potential to an electrode, or the like).

As can be seen in FIG. 22 , in one form, the robotic arm cart 800 may be configured to actuate one or more surgical tools, generally designated as 900. Various robotic surgery systems and methods employing master controller and robotic arm cart arrangements are disclosed in U.S. Pat. No. 6,132,368, entitled MULTI-COMPONENT TELEPRESENCE SYSTEM AND METHOD, the entire disclosure of which is hereby incorporated by reference herein.

In various forms, the robotic arm cart 800 includes a base 702 from which, in the illustrated embodiment, surgical tools 900 may be supported. In various forms, the surgical tool(s) 900 may be supported by a series of manually articulatable linkages, generally referred to as set-up joints 804, and a robotic manipulator 806. In various embodiments, the linkage and joint arrangement may facilitate rotation of a surgical tool around a point in space, as more fully described in U.S. Pat. No. 5,817,084, entitled REMOTE CENTER POSITIONING DEVICE WITH FLEXIBLE DRIVE, the entire disclosure of which is hereby incorporated by reference herein. The parallelogram arrangement constrains rotation to pivoting about an axis 812 a, sometimes called the pitch axis. The links supporting the parallelogram linkage are pivotally mounted to set-up joints 804 (FIG. 22 ) so that the surgical tool further rotates about an axis 812 b, sometimes called the yaw axis. The pitch and yaw axes 812 a, 812 b intersect at the remote center 814, which is aligned along an elongate shaft of the surgical tool 900. The surgical tool 900 may have further degrees of driven freedom as supported by the manipulator 806, including sliding motion of the surgical tool 900 along the longitudinal axis “LT-LT”. As the surgical tool 900 slides along the tool axis LT-LT relative to manipulator 806 (arrow 812 c), the remote center 814 remains fixed relative to the base 816 of the manipulator 806. Hence, the entire manipulator is generally moved to re-position the remote center 814. Linkage 808 of manipulator 806 may be driven by a series of motors 820. These motors actively move linkage 808 in response to commands from a processor of a control system. The motors 820 may also be employed to manipulate the surgical tool 900. Alternative joint structures and set up arrangements are also contemplated. Examples of other joint and set up arrangements, for example, are disclosed in U.S. Pat. No. 5,878,193, entitled AUTOMATED ENDOSCOPE SYSTEM FOR OPTIMAL POSITIONING, the entire disclosure of which is hereby incorporated by reference herein.

While the data communication between a robotic component and the processor of the robotic surgical system is primarily described herein with reference to communication between the surgical tool and the master controller 701, it should be understood that similar communication may take place between circuitry of a manipulator, a set-up joint, an endoscope or other image capture device, or the like, and the processor of the robotic surgical system for component compatibility verification, component-type identification, component calibration (such as off-set or the like) communication, confirmation of coupling of the component to the robotic surgical system, or the like. In accordance with at least one aspect, various surgical instruments disclosed herein may be used in connection with other robotically-controlled or automated surgical systems and are not necessarily limited to use with the specific robotic system components shown in FIGS. 21-23 and described in the aforementioned references.

It is common practice during various laparoscopic surgical procedures to insert a surgical end effector portion of a surgical instrument through a trocar that has been installed in the abdominal wall of a patient to access a surgical site located inside the patient's abdomen. In its simplest form, a trocar is a pen-shaped instrument with a sharp triangular point at one end that is typically used inside a hollow tube, known as a cannula or sleeve, to create an opening into the body through which surgical end effectors may be introduced. Such arrangement forms an access port into the body cavity through which surgical end effectors may be inserted. The inner diameter of the trocar's cannula necessarily limits the size of the end effector and drive-supporting shaft of the surgical instrument that may be inserted through the trocar.

Regardless of the specific type of surgical procedure being performed, once the surgical end effector has been inserted into the patient through the trocar cannula, it is often necessary to move the surgical end effector relative to the shaft assembly that is positioned within the trocar cannula in order to properly position the surgical end effector relative to the tissue or organ to be treated. This movement or positioning of the surgical end effector relative to the portion of the shaft that remains within the trocar cannula is often referred to as “articulation” of the surgical end effector. A variety of articulation joints have been developed to attach a surgical end effector to an associated shaft in order to facilitate such articulation of the surgical end effector. As one might expect, in many surgical procedures, it is desirable to employ a surgical end effector that has as large a range of articulation as possible.

Due to the size constraints imposed by the size of the trocar cannula, the articulation joint components must be sized so as to be freely insertable through the trocar cannula. These size constraints also limit the size and composition of various drive members and components that operably interface with the motors and/or other control systems that are supported in a housing that may be handheld or comprise a portion of a larger automated system. In many instances, these drive members must operably pass through the articulation joint to be operably coupled to or operably interface with the surgical end effector. For example, one such drive member is commonly employed to apply articulation control motions to the surgical end effector. During use, the articulation drive member may be unactuated to position the surgical end effector in an unarticulated position to facilitate insertion of the surgical end effector through the trocar and then be actuated to articulate the surgical end effector to a desired position once the surgical end effector has entered the patient.

Thus, the aforementioned size constraints form many challenges to developing an articulation system that can effectuate a desired range of articulation, yet accommodate a variety of different drive systems that are necessary to operate various features of the surgical end effector. Further, once the surgical end effector has been positioned in a desired articulated position, the articulation system and articulation joint must be able to retain the surgical end effector in that locked position during the actuation of the end effector and completion of the surgical procedure. Such articulation joint arrangements must also be able to withstand external forces that are experienced by the end effector during use.

Various surgical instruments employ a variety of different drive shaft arrangements that serve to transmit drive motions from a corresponding source of drive motions that is supported in a handle of the surgical instrument or other portion of an automated or robotically controlled system. These drive shaft arrangements must be able to accommodate significant articulated orientations of the end effector while effectively transmitting such drive motions across the articulation joint of the surgical instrument. In addition, due to the above-mentioned size constraints dictated by the sizes of trocars through which the instrument shafts must be inserted, these drive shaft components must occupy as little space as possible within the shaft. To accommodate such requirements, many drive shaft arrangements comprise several movable elements that are coupled together in series. The small sizes (e.g., 4 mm diameter) and numbers of components lead to difficult and lengthy assembly procedures that add to the cost and complexity of the device.

As further described herein, a powered stapling device can include two independently rotatable drive members: a first rotary drive member configured to effect closing of the jaws of the end effector and a second rotary drive member configured to effect firing of a staple cartridge installed in the end effector. The first and second rotary drive members are flexible and configured to extend through at least one articulation joint. In such instances, the first and second rotary drive members can transmit rotary actuation motions through the articulation joint(s) when in a non-flexed configuration and when in a flexed configuration. Exemplary rotary drive members are further described herein.

The powered stapling assembly further comprises a first jaw, a second jaw, a closure drive comprising the first rotary drive member extending through the articulation joint, and a firing drive comprising the second rotary drive member extending through the articulation joint. The second rotary drive member can be rotatable independent of the first rotary drive member. The closure drive can be activated by a closure trigger, for example, whereupon an actuation of the closure drive effects a rotation of the first rotary drive member, which transmits a rotary motion through the articulation joint to a closure screw. The closure drive further comprises a closure wedge threadably coupled to the closure screw, wherein the closure wedge is configured to engage the first jaw to move the first jaw from an open position to a closed position upon rotation of the first rotary drive member.

The firing drive can be activated by a firing trigger, for example, which is separate from the closure trigger. The rotation of the second rotary drive member is separate from the rotation of the first rotary drive member, and a closure motion is separate and distinct from a firing motion. Activation of the firing drive effects a rotation of the second rotary drive member, which transmits a rotary motion through the articulation joint to a firing screw. The firing drive further comprises a firing member threadably coupled to the firing screw, wherein the firing member is configured to camming engage the first jaw and the second jaw and to move a cutting member and/or a staple-firing sled upon rotation of the second rotary drive member.

In various instances, at least one component in the powered stapling device can be a 3D-printed component. 3D-printed components can be incorporated into an articulation system, a closure/grasping system, and/or a firing system, as further described herein. 3D printing technology can be utilized to improve component capabilities in certain instances. For example, 3D printing can allow the printed component to exhibit metamaterial properties, such that the 3D-printed components exhibits greater structural strength and stiffness while allowing precision in the forming of small detailed features and optimizing other properties of the component such as selective flexibility and/or lubrication, for example. Exemplary 3D-printed components for the powered stapling device are further described herein and include the flexible rotatable drive member(s), e.g. serial 3D-printed universal joints, the firing member or I-beam, and/or the staple cartridge and/or sub-components thereof. In one instance, the staple cartridge can be a composite plastic-metal 3D-printed component. 3D printing of various components and considerations therefor are further described herein.

A method of stapling with such surgical stapling assemblies is also contemplated. The method can include obtaining the surgical stapling assembly and activating, by the closure trigger, the closure drive, wherein the closure wedge is configured to engage the first jaw to move the first jaw from an open position to a closed position upon a rotation of the first rotary drive member. The method can further includes activating, by the firing trigger, the firing drive, wherein the firing member is configured to camming engage the first jaw and the second jaw and to advance a cutting member and a staple-firing sled during a firing motion upon a rotation of the second rotary drive member. Various applications of 3D-printed components in such assemblies are further described herein.

Firing elements and various end effector components are subjected to high loads during the firing stroke. The loads imparted may cause deformation and/or wear of the firing elements and/or end effector components. For example, during a firing stroke, a firing element which cammingly engages an anvil and an elongate channel of an end effector may at least partially ride within an anvil slot in the anvil and along the bottom of the elongate channel. During firing, the anvil is in its closed position, however, as the firing element moves through the end effector, the anvil may attempt to move away from the elongate channel due to the forces associated with firing. For example, the force to form the staples, the force to sever the tissue, and the reactionary forces from the clamped tissue as it is cut and stapled. These forces are imparted onto the firing element during firing and can cause deformation or wear on the firing element and/or other end effector components.

In various embodiments, end effector components may be constructed using three dimensional (“3D”) printing to improve component capabilities. In certain instances, 3D printing can allow components to exhibit metamaterial properties to aid in lowering the force to fire. A metamaterial is a synthetic composite material with a structure such that it exhibits properties not usually found in natural materials. 3D printing is one technique used to create a metamaterial to form structures with two or more materials. As such, 3D printing allows for the creation of complex geometries and/or material combinations that may otherwise be too costly and time consuming to manufacture or may even be impossible to manufacture absent 3D printing technology.

In various embodiments, a firing element may be 3D printed such that its main body acts as a spring to allow the upper and/or lower cam portions to flex and move to contact the anvil and elongate channel at an angle of reduced resistance.

FIGS. 24 and 25 depict a firing member 41000 for use with a surgical instrument, such as the surgical instruments disclosed herein. The firing member 41000 is deformable from a first or unloaded configuration (FIG. 24 ) in the absence of a firing load to a second or expanded configuration (FIG. 25 ) under a firing load. Additional configurations, such as intermediate configurations between the unloaded configuration and the expanded configuration, for example, are also contemplated in response to different firing loads. The firing member 41000 comprises a proximal firing bar portion 41100 and a distal head portion 41200 extending from the firing bar portion 41100. Specifically, the firing bar portion 41100 includes a distal protrusion 41110 that extends into a cutout portion 41250 defined in the proximal end of the distal head portion 41200. The distal protrusion 41110 includes arcuate portions and a blunt distal end for driving engagement with the distal head portion 41200. Such an arrangement permits assembly of the firing bar portion 41100 to the distal head portion 41200.

The distal head portion 41200 further includes an upper portion 41210 and a lower portion 41220 that are movable relative to one another. The cutout portion 41250 is defined in both the upper and lower portions 41210, 41220. As such, the distal end of the firing bar portion 41100 is in engagement with both the upper portion 41210 and the lower portion 41220 of the distal head portion 41200. Further, the distal head portion 41200 includes a protruding nose 41230 that extends distally. The protruding nose 41230 is configured to engage and drive a sled of a surgical staple cartridge distally during a firing stroke, for example. The protruding nose 41230 can be configured to defeat a firing lockout of a surgical instrument, for example. Further, the distal head portion 41200 includes a knife portion or cutting member for severing the tissue of a patient during a firing stroke of the firing member 41000 in certain aspects of the present disclosure.

Further to the above, the distal head portion 41200 comprises a flexible portion 41240 that connects the upper portion 41210 and the lower portion 41220 of the distal head portion 41200. Specifically, the flexible portion 41240 comprises a top end 41260 defined in the upper portion 41210, and a bottom end 41270 defined in the lower portion 41220. In at least one embodiment, the flexible portion 41240 is embedded into the distal head portion 41200. However, other attachment arrangements are envisioned for the upper portion 41220, the lower portion 41220, and the flexible portion 41240. For example, the entire distal head portion 41200 may be 3D printed having different materials for the different portions of the distal head 41200.

In at least one embodiment, the distal head 41200 is comprised of a first material and the flexible portion 41240 is comprised of a second material that is different from the first material. For example, the flexible portion 41240 may be comprised of aluminum and the remainder of the distal head portion 41200 may be comprised of stainless steel. However, other embodiments are envisioned with different materials for the distal head portion 41200 and the flexible portion 41240 such as plastic, ABS, rubber, and/or various polymers. In the illustrated embodiment, the flexible portion 41240 is shaped like an “I” having an upright portion and orthogonal flanges at both ends of the upright portion, however other embodiments are envisioned with different cross-sectional shapes for the flexible portion 41240.

Further to the above, the distal head portion 41200 comprises an upper cam member defined on the upper portion 41210, and a lower cam member defined on the lower portion 41220. The upper and lower cam members are configured to cammingly engage a first jaw and a second jaw of an end effector of a surgical instrument to approximate the first jaw and the second jaw relative to one another during a firing stroke. As such, the upper portion 41210 and the lower portion 41220 may separate to accommodate a transverse load imparted on the distal head portion 41200 during the firing stroke. Specifically, as depicted in FIG. 25 , a gap 41280 may form between the upper portion 41210 and the lower portion 41220 of the distal head 41200 during the firing stroke. In the illustrated embodiment, the upper portion 41210 moves away from the lower portion 41240, which is stationary. The distal end of the firing bar 41100 includes an extension 41120, which extends beyond the height of the upper portion 41210 when the distal head portion 41200 and flexible portion 41240 are undeformed or non-expanded. Further, the extension 41120 of the firing bar 41100 is tall enough to accommodate the expansion of the distal head 41200. As such, when the distal head 41200 is expanded, the extension 41120 of the firing bar 41100 can maintain driving contact with the proximal end of the distal head 41200.

In any event, other embodiments are envisioned where both the upper portion 41210 and the lower portion 41220 move during a firing stroke in response to a firing load. Further, other embodiments are envisioned where only the lower portion 41220 moves during a firing stroke.

Further to the above, when the distal head 41200 extends vertically to an expanded configuration, the flexible portion 41240 stretches vertically while maintaining the connection between the upper and lower portions 41210, 41220 of the distal head 41200. When the flexible portion 41240 is stretched, an intermediate portion 41265 of the flexible portion 41240 may neck down or narrow to accommodate a transverse load as depicted in FIG. 25 .

FIG. 26 depicts a surgical instrument 42000 comprising an elongate shaft 42100, an end effector 42200 extending from the elongate shaft 42100, and a firing member 42300 configured to move relative to the elongate shaft 42100 and the end effector 42200 to perform a firing stroke. The elongate shaft 42100 may be a closure tube for opening and closing a pair of jaws 42240, 42210 of the end effector 42200, for example. The firing member 42300 comprises a proximal firing bar portion 42310 and a distal head portion 42320 extending therefrom. Specifically, the proximal firing bar portion 42310 includes a distal protrusion 42312 that extends into a cutout 42336 defined in the proximal end of the distal head portion 42320. Such an arrangement facilitates the assembly of the proximal firing bar portion 42310 to the distal head portion 42320.

Further to the above, the distal head portion 42320 is a two-part assembly formed from an upper portion 42330 and a lower portion 42340 that are movable relative to one another. The upper portion 42330 comprises a distally-protruding lower foot 42334 and the lower portion 42340 comprises a proximally-protruding upper foot 42342 positioned to interact and selectively interlock with the distally-protruding lower foot 42334. An opening 42400 is defined between the distally-protruding lower foot 42334 and the proximally-protruding upper foot 42342 when the upper portion 42330 and the lower portion 42340 are in a collapsed configuration, as depicted in FIG. 26 . The opening 42400 permits the upper portion 42330 to move relative to the lower portion 42340, to an extent, during a firing stroke of the distal head portion 42320, as discussed in greater detail below.

Further to the above, the distally-protruding lower foot 42334 extends into a pocket, or cavity 42346, in the lower portion 42340. The cavity 42346 defines a flange 42348 on the proximal end of the lower portion 42340. The flange 42348 extends toward the upper portion 42330 and prevents the distally-protruding lower foot 42334 of the upper portion 42330 from becoming detached from the lower portion 42340. Specifically, the opening 42400 height is smaller than the height of the flange 42348 and, thus, the upper portion 42330 and the lower portion 42340 are prevented from detaching in the longitudinal direction.

Further to the above, the upper portion 42330 and the lower portion 42340 of the distal head portion 42320 can be connected via a flexible attachment member, such as the flexible portion 41240 of FIG. 24 , for example, in certain instances. Further, in at least one aspect, the upper portion 42330 and the lower portion 42340 of the distal head portion 42320 can comprise two completely separate components that are not attached, but are held together due to the internal geometry of the elongate shaft 42100 and end effector 42200.

Further to the above, The upper portion 42330 comprises a first cam member configured to cammingly engage the first jaw 42240 of the end effector 42200 during a firing stroke, and the lower portion 42340 comprises a second cam member configured to cammingly engage the second jaw 42210 of the end effector 42200 during the firing stroke. As such, the first cam member and the second cam member are configured to approximate the first jaw 42240 and the second jaw 42210 of the end effector 42200 during the firing stroke. In the illustrated embodiment, the first jaw 42240 comprises a movable anvil, and the second jaw 42210 comprises an elongate channel configured to receive a staple cartridge 42220. The anvil 42240 is movable relative to the elongate channel 42210 between an open position and a closed position. Further, the firing member 42300 is configured to move a sled 42230 of the staple cartridge 42220 through the end effector 42200 to eject staples from the staple cartridge 42220.

In use, as the firing member 42300 distally advances from the unfired position depicted in FIG. 26 , the distal head portion 42320 advances beyond the distal end of the elongate shaft 42100, which can allow for expansion of the distal head portion 42320 under certain firing loads. The distal head portion 42320 advances into the end effector 42200 such that the upper cam member engages the anvil 42240 and the lower cam member engages the elongate channel 42210. As such, the first cam member on the upper portion 42330 is in camming engagement with the movable anvil 42240 during the firing stroke, and the second cam member on the lower portion 42340 is in camming engagement with the elongate channel 42210 during the firing stroke.

The upper portion 42330 and the lower portion 42340 are capable of separating or moving farther apart vertically during the firing stroke. For example, when the anvil 42240 is in its closed position and the firing stroke has commenced, forces due to staple firing, cutting, and/or patient tissue may deflect or move the anvil 42240 away from the elongate channel 42210. The expansion of the distal head portion 42320 can accommodate such movement or deflection. In certain instances, the expansion of the firing member 42320 can accommodate entry of the upper cam member on the upper portion 42330 into an anvil channel of the anvil 42200 if the anvil channel is misaligned. Further, the expansion of the distal head portion 42320 is limited by the distally-protruding lower foot 42334 and the proximally-protruding upper foot 42342, which are drawn closer together to close the space 42400 therebetween and eventually engage one another to limit the extent of expansion of the distal head portion 42320.

Further to the above, after the distal head portion 42320 has been distally advanced and expanded, the distal head portion 42320 can be retracted back to the home or unfired position illustrated in FIG. 26 . During retraction, a first cam surface 42338 on the upper portion 42330 engages a second cam surface 42120 on the distal end of the elongate shaft 42100. The first and second cam surfaces 42338, 42120 interact to compress the distal head 42320 into its non-expanded state (FIG. 26 ).

Further to the above, the lower portion 42340 of the distal head portion 42320 comprises a cutout portion 42344 defined in the distal end of the lower portion 42340. The cutout portion 42344 is configured to receive a proximal nose portion 42232 of the sled 42230 therein. As such, a distal advancement of the distal head portion 42320 will advance the sled 42230 through the staple cartridge 42220 to eject the staples. Further, the distal head portion 42320 comprises a knife portion 42332 configured to sever the tissue of a patient during the firing stroke.

FIGS. 27 and 28 depict a stapling attachment 43000 for use with a surgical instrument, such as those described herein. The stapling attachment 43000 comprises an elongate shaft 43100 attachable to a handle and/or housing, and an end effector 43200 extending from the elongate shaft 43100. The end effector 43200 comprises a first jaw, or anvil 43210, and a second jaw, or elongate channel 43220. The anvil 43210 is movable relative to the elongate channel 43220 between an open position and a closed position in response to a closure motion from a closure system. The anvil 43210 comprises landing portions 43212 on its proximal end. Further, a medium and/or low durometer material 43214 extends from the landing portion 43212. The low durometer material 43214 can comprise rubber, plastic, a polymer and/or any other suitable material, for example. The material 43214 has a lower durometer than the landing portion 43212. In one aspect, the landing portion 43212 can be metal, and the material 43214 can be rubber, for example.

Further to the above, the elongate channel 43220 is configured to receive a staple cartridge 43230 therein. The staple cartridge 43230 comprises a proximal cartridge tail 43232 with substantially flat portions on both sides of a cartridge slot 43234. Typically, the cartridge tail 43232 is configured to interact with the landing portions 43212 of the anvil 43210 when the anvil 43210 is in its closed position. In the illustrated embodiment, the low durometer material 43214 acts as a semi-compressible material between the landing portions 43212 of the anvil 43210 and the cartridge tail 43232. As such, the anvil 43210 is capable of floating relative to the staple cartridge 43230 in response to the forces exerted by the closure system and/or the firing system. Specifically, due to the compressible nature of the low durometer material 43214, the anvil 43210 can flex and/or deflect relative to the staple cartridge 43230 more than would be possible without the low durometer material 43214 present on the landing portions 43214.

Other embodiments are envisioned where the low durometer material 43214 is defined as part of the anvil 43210 and flush with the landing portions 43212 of the anvil 43210. In such an arrangement, the low durometer material 43214 may allow for over-closing of the anvil 43210 relative to the staple cartridge 43230. Specifically, a firing member engages the anvil slot 43216 and the elongate channel 43220 to close the anvil 43200 relative to the staple cartridge 43230 during an initial closing operation. During the initial closing operation of the anvil 43200, the compressible low durometer material 43214 flush with the landing portions 43212 can abut and cause interference with the rigid cartridge tail 43232 of the staple cartridge 43230. Because the low durometer material 43214 is compressible, the proximal portion of the anvil 43200 is capable of flexing to overcome the interference between the landing portions 43212 and the cartridge tail 43232. As the firing member advances through the staple cartridge 43230, the low durometer material 43214 may further compress against the rigid cartridge tail 43232. The two surfaces 43214, 43232 can move past the point of interference to allow the firing member to complete the firing stroke without binding.

Further to the above, the low durometer material 43214 may be more compressible than the anvil 43210 and/or the cartridge 43230. Further, the low durometer material 43214 may reduce the forces on a firing member which travels through the anvil 43210 and the staple cartridge slot 43234. Specifically, a firing member with an upper and lower cam member, such as those described herein, can move within the end effector 43200. For example, the upper cam of the firing member moves through anvil slot 43216. Due to the compressibility of the low durometer material 43214, the anvil slot 43216 can flex relative to the staple cartridge 43230. As such, less force will be exerted on the upper cam member of the firing member during closing and/or firing as compared to if the low durometer material 43214 were not present.

Further to the above, embodiments are envisioned which incorporate the low durometer material 43214 and the expanding firing members 41000, 42320 of FIGS. 24-26 into an end effector. The compressibility of the low durometer material 43214 of an anvil, for example, in combination with the expanding capabilities of the firing members 41000 or 42320, for example, can provide an end effector with greater variability during the firing stroke. Specifically, the low durometer material 43214 can allow the anvil to float more relative to the cartridge, and the expanding firing members 41000, 42320 can allow for greater leeway in alignment between the firing member flanges and the anvil slot.

In various embodiments, firing members, (e.g., I-beams or E-beams) can be constructed to have complex 3D printed geometries incorporated into the main body, which can act as a spring and allow the upper cam portion to flex and move with the anvil ledge to an angle of reduced or least resistance. Such geometric complex printed structures allow for metamaterial behaviors. For example, a metal I-beam could have portions that act as a solid metal structure and alternative portions having geometries that are designed to allow for greater bending and/or stretching to permit the I-beam to focus its deflection in a location and/or orientation to align the I-beam to the use and/or load. Exemplary embodiments of such !-beams are discussed in greater detail below.

FIG. 29 depicts a firing member 44000 comprising a body portion 44100, a pair of upper cam members 44140 extending laterally from both sides of the body portion 44100, and a pair of lower cam members 44150 extending laterally from both sides of the body portion 44100. The upper cam members 44140 are configured to cammingly engage an upper jaw, or anvil, of an end effector during a firing stroke, and the lower cam members 44150 are configured to cammingly engage a lower jaw, or elongate channel of the end effector during the firing stroke. The elongate channel is configured to receive a staple cartridge including staples that can be ejected when the firing member 44000 is advanced within the staple cartridge. Exemplary jaws, anvil, and staple cartridges for use with the firing member 44000 are further described herein.

Further to the above, the body portion 44100 comprises a longitudinal opening 44110 extending through the body portion 44100 and defining a longitudinal axis LA. The body portion 44100 further comprises a distal nose portion 44130 extending distally from the body portion 44100. The longitudinal opening 44110 is configured to receive a rotary firing driver, such as firing screw 261 (see, e.g. FIG. 16 ) described above. The body portion 44100 further comprises a cutout region 44120 configured to receive a firing drive nut 44200. The firing drive nut 44200 is configured to threadably engage the rotary firing driver to convert rotary motion of the rotary firing driver into translation of the firing member 44000. The firing drive nut 44200 comprise a pair of laterally-extending members 44210 that extend from both sides of the firing drive nut 44200. The pair of laterally-extending members 44210 are aligned with the pair of lower cam members 44150. As such, the cam members 44210, 44150 cooperate to cammingly engage the lower jaw of the end effector during the firing stroke.

Further to the above, the firing member 44000 further comprises flexible portions 44160 positioned intermediate the body portion 44100 and the pair of upper cam members 44140. In other words, the flexible portions 44160 attach at least a portion of the upper cam members 44140 to the body portion 44100. As can be seen in FIG. 31 , the flexible portions 44160 comprise a three-dimensional lattice comprising an array of cavities, gaps, and/or cutouts. The array of cavities form a plurality of arcuate bars 44162 arrange in an array. The flexible portion 44160 comprises an overall cross-sectional density that is reduced compared to the adjacent upper cam member 44140 and the body portion 44100. As such, the flexible portions 44160 can flex, bend, and/or deflect a greater amount than the adjacent upper cam member 44140 and the body portion 44100. As can be seen in FIG. 31 , the arcuate bars 44162 and corresponding cutout regions are symmetrical about the body portion 44100. However, other embodiments are envisioned where the arcuate bars 44162 are of varying shapes and sizes on the same side and/or or on opposite sides of the body portion 44100. In certain instances, the array of cavities can form linear bars, for example. In at least one embodiment, the flexible portion 44160 comprises a three-dimensional honeycomb lattice, for example. The three-dimensional lattice of the flexible portions 44160 can have a reduced density in comparison to adjacent portions. Moreover, the flexible portions 44160 can have a significantly reduced infill percentage in comparison to adjacent portions.

Further to the above, as can be seen in FIG. 31 , the flexible portions 44160 extend longitudinally along only a portion of the upper cam members 44140 from the distal end of the upper cam members 44140 and terminate in an intermediate portion of the upper cam members 44140. As such, the distal end of the upper cam members 44140 is more flexible than the proximal end of the upper cam members 44140. Other embodiments are envisioned where the flexible members 44160 extend along the entire length of the upper cam members 44140 and/or only at the proximal end of the upper cam members 44140. Further still, other embodiments are envisioned where the flexible portions 44160 are in the middle of the upper cam members 44140 with more rigid portions at the proximal and distal ends.

Further to the above, in at least one embodiment, the firing member 44000 may be constructed using a 3D printing process. Infill and solid wall parts are traditionally used to fabricate objects that are lightweight and strong. 3D printed parts are manufactured with a specific infill percentage. The printing process uses a crosshatch or other pattern for interior surfaces to form cells within the infill portion of the 3D printed part. The density of this pattern is referred to as the infill percentage. For example, it is common to have 1-2 mm thick walls, and to have 25-35% of the part solid inside of the walls. When building parts with powder based processes, such as 3D printing, it is important to note that powder must have escape holes to ensure powder reclamation after the part is fabricated. Infill for parts can be 2D like a honeycomb, or 3D like a gyroid. Different patterns have different strength profiles. For example, patterns with larger cells can be more flexible than patterns with smaller cells. Due to the freedom of geometry, the geometry can be variably thickened and thinned to ensure that flexion can occur at a desired location and a desired amount.

Different geometries and infill percentages could be used at different locations in the firing member 44000 to achieve different degrees of deformation and/or predispositions to different directions of deformation. In certain instances, the leading end of the upper cam portion 44140 can have a different infill percentage or infill matrix/geometry than adjacent portions of the firing member 44000 to maintaining the rigidity of the proximal end of the upper cam member 44140, as depicted in FIG. 31 . An increased deflection of the leading edge of the upper cam member 44140 can facilitate alignment of the upper cam member 44140 with the anvil ledge at the outset of the firing motion, which can avoid jamming or binding of the firing member in certain instances, such as when thick and/or tough tissue is clamped between the jaws. Other embodiments are envisioned where the middle of the upper cam member 44140 is flexible with both of the ends more rigid. As such, by varying the firing member geometry with 3D printing, the location and amount of flexion can be controlled based on the amount of force anticipated.

FIGS. 32 and 33 depict a firing member 45000 comprising a body portion 45100, a pair of upper cam members 45140 extending laterally from both sides of the body portion 45100, and a pair of lower cam members 45150 extending laterally from both sides of the body portion 45100. The upper cam members 45140 are configured to cammingly engage an upper jaw, or anvil, of an end effector during a firing stroke, and the lower cam members 45150 are configured to cammingly engage a lower jaw, or elongate channel of the end effector during the firing stroke. The elongate channel is configured to receive a staple cartridge including staples that can be ejected when the firing member 44000 is advanced within the staple cartridge. Exemplary jaws, anvil, and staple cartridges for use with the firing member 45000 are further described herein.

Further to the above, the body portion 45100 comprises a longitudinal opening 45110 extending through the body portion 45100, similar to the longitudinal opening 44110 (see FIG. 29 ). The longitudinal opening 45110 is configured to receive a rotary firing driver, such as firing screw 261 (see, e.g. FIG. 16 ) described above. The body portion 45100 further comprises a distal nose portion 45130 extending distally from the body portion 45100. The body portion 45100 further comprises a cutout region 45120 configured to receive a firing drive nut 45200. The firing drive nut 45200 is configured to threadably engage the rotary firing driver to convert rotary motion of the rotary firing driver into translation of the firing member 45000. The firing drive nut 45200 comprise a pair of laterally-extending cam members 45210 that extend from both sides of the firing drive nut 45200. The pair of laterally-extending cam members 45210 are aligned with the pair of lower cam members 45150. As such, the cam members 45210, 45150 cooperate to cammingly engage the lower jaw of the end effector during the firing stroke.

Further to the above, the firing member 45000 further comprises a flexible portion 45160 positioned intermediate the upper cam members 45140 and the lower cam members 45150, 45210. The flexible portion 45160 comprises a first plurality of arcuate slots 45170 extending laterally through the body portion 45100, and a second plurality of arcuate slots 45180 extending laterally through the body portion 45100. In the illustrated embodiment, the first plurality of arcuate slots 45170 are curved in a direction which resembles a backward C-shape, and the second plurality of arcuate slots are curved in the opposite direction which resembles a forward C-shape. However, other embodiments are envisioned with different curvatures or combination of curvatures for the arcuate slots 45170. Further, in the illustrated embodiment five first arcuate slots 45170 and five second arcuate slots 45180 are depicted, however, other embodiments are envisioned with more or less than five arcuate slots for each of the first plurality or arcuate slots 45170 and each of the second plurality of arcuate slots 45180.

In any event, the body portion 45100 further comprises a first cutout region 45175 on its distal end that is defined by the first plurality of arcuate slots 45170, and a second cutout region 45185 on its proximal end that is defined by the second plurality of arcuate slots 45180. The arcuate slots 45170, 45180 and the cutout regions 45175, 45185 permit the firing member 45000 to flex and/or deflect when a load is applied to the firing member 45000, as discussed in greater detail below.

Referring primarily to FIG. 33 , an anvil channel or anvil ledge 45300 and an elongate channel 45400 for receiving a staple cartridge are depicted in dashed lines for the purpose of simplicity. In use, when the firing member 45000 is driven within an end effector, the upper cam members 45140 are configured to cammingly engage the anvil (i.e., ride along the anvil ledge 45300) during the firing stroke. Further, the lower cam members 45150, 45210 are configured to cammingly engage the bottom of the elongate channel 45400 during the firing stroke. During the firing stroke of the firing member 45000, the upper cam members 45140 may experience a lateral force F applied by the anvil ledge 45300 when the anvil ledge 45300 moves away from the elongate channel 45400. For example, the lateral force F may be due to clamping of patient tissue, firing of the staples, or cutting of the patient tissue. In at least one embodiment, the lateral force F may be applied to the upper cam members 45150 upon entry into the anvil channel, for example. In any event, the firing member 45000 is configured to flex and/or deflect due to the flexible portion 45160 during the firing stroke. Specifically, in FIG. 32 the firing member 45000 is in a relaxed state corresponding to an unloaded configuration, and in FIG. 33 the firing member 45000 is in an unrelaxed, or deflected state corresponding to a loaded configuration.

Further to the above, due to the lateral force F applied to the upper cam members 45140, the upper cam members 45140 rotate in a clockwise direction which causes the flexible portion 45160 and the body portion 45100 to flex and/or deflect to enable the firing member 45000 to change shape based on the load applied. Specifically, the first plurality of arcuate slots 45170 are configured to stretch and the second plurality of arcuate slots 45180 are configured to compress when the lateral force F is applied. Moreover, the first cutout region 45175 elongates and the second cutout region 45185 compresses when the lateral force F is applied. As such, the firing member body 45100 can flex and/or deflect to accommodate the lateral force F.

Further to the above, during use, the upper cam members 45140 are configured to ride along the anvil ledge 45300 within a longitudinal anvil slot. Upon initial entry of the upper cam members 45140 into the anvil slot, the upper cam members 45140 may be misaligned due to the varying amounts of tissue (i.e., thick and thin tissue) grasped between the jaws. As such, the flexible portion 45160 permits the upper cam members 45140 to flex and/or deflect to properly align the upper cam members 45140 with the anvil slot, for example. Further, the varying amounts of tissue grasped between the jaws may cause the anvil ledges 45300 to move away from the elongate channel 45400 during a firing stroke of the firing member 45000. As such, the upper cam members 45140 may become misaligned with the anvil slot during firing. However, the flexible portion 45160 permits the upper cam members 45140 to flex and/or deflect to compensate for the varying amounts of tissue to prevent the upper cam members 45140 from jamming within the anvil slot when the upper cam members 45140 are not properly aligned within the anvil slot.

Further to the above, in at least one embodiment, the firing member 45000 can comprise a longitudinal slot extending through the flexible portion 45160 to permit one lateral side of the firing member 45000 to flex at least partially independent of another lateral side of the firing member 45000. The longitudinal slot may be similar to longitudinal slot 46170 (see FIG. 34 ) discussed in greater detail below, for example.

FIGS. 34-36 depict a firing member 46000 comprising a body portion 46100, a pair of upper cam members 46140 extending laterally from both sides of the body portion 46100, and a pair of lower cam members 46150 extending laterally from both sides of the body portion 46100. The upper cam members 46140 are configured to cammingly engage an upper jaw, or anvil, of an end effector during a firing stroke, and the lower cam members 46150 are configured to cammingly engage a lower jaw, or elongate channel of the end effector during the firing stroke. The elongate channel is configured to receive a staple cartridge including staples that can be ejected when the firing member 46000 is advanced within the staple cartridge. Exemplary jaws, anvil, and staple cartridges for use with the firing member 46000 are further described herein.

Further to the above, the body portion 46100 comprises a longitudinal opening 46110 extending through the body portion 46100 and defining a longitudinal axis LA. The longitudinal opening 46110 is configured to receive a rotary firing driver, such as firing screw 261 (see, e.g. FIG. 40 ) described above. The body portion 46100 further comprises a distal nose portion 46130 extending distally from the body portion 46100. The body portion 46100 further comprises a cutout region 46120 configured to receive a firing drive nut 46200. The firing drive nut 46200 is configured to threadably engage the rotary firing driver to convert rotary motion of the rotary firing driver into translation of the firing member 46000. The firing drive nut 46200 comprise a pair of laterally-extending cam members 46210 that extend from both sides of the firing drive nut 46200. The pair of laterally-extending cam members 46210 are aligned with the pair of lower cam members 46150. As such, the cam members 46210, 46150 cooperate to cammingly engage the lower jaw of the end effector during the firing stroke.

Further to the above, the firing member 46000 further comprises a flexible portion, or lattice portion, 46160 positioned intermediate the upper cam members 46150 and the lower cam members 46150. In the illustrated embodiment, the lattice portion 46160 is bifurcated by a longitudinal slot 46170 which extends parallel to the longitudinal axis LA. The longitudinal slot 46170 extends through the body portion 46100 from the proximal end to the distal end. As such, the lattice portion 46160 is divided into a first side 46180 and a second side 46190. The first side 46180 of the lattice portion 46160 comprises a plurality of slots 46182 oriented transverse to the longitudinal axis LA in a first direction. The second side 46190 of the lattice portion 46160 comprises a plurality of slots 46192 oriented transverse to the longitudinal axis LA in a second direction that is opposite the first direction. The plurality of slots 46182, 46192 reduce the overall cross-sectional density of the firing member 46000 within the lattice portion 46160. In other words, the lattice portion 46160 is less dense (e.g. lower infill percentage) than the adjacent portions of the body portion 46100 of the firing member 46000. Further, the longitudinal slot 46170, which bifurcates the lattice portion 46160, permits the first side 46180 of the lattice 46160 to slide past the second side 46190 of the lattice 46160, and vice versa, and/or permits the first side 46180 of the lattice 46160 to stretch vertically while the second side 46190 is compressed vertically, or vice versa. Without the longitudinal slot 46170, sliding and deflection of the first and second sides 46180, 46190 relative to one another would be limited.

Further to the above, the first side 46180 comprises a notch 46185 on the proximal end of the body portion 46100, and the second side 46190 comprises a notch 46195 on the proximal end of the body portion 46100. The notches 46185, 46195 provide greater flexion and/or deflection of the proximal end of the body portion 46100 as compared to the distal end of the body portion 46100. Moreover, in the illustrated embodiment, the notches 46185, 46195 are positioned on the proximal end of the body portion 46100. However, other embodiments are envisioned where the notches 46185, 46195 are positioned on the distal end of the body portion 46100 for the opposite effect. Further still, other embodiments are envisioned with notches on the proximal and distal ends of the body portion 46100, see FIG. 38 and accompanying description below.

In use, when the firing member 46000 is advanced into an end effector, the upper cam members 46140 engage an upper jaw, or anvil of the end effector, and the lower cam members 46150, 46210 engage a lower jaw, or elongate channel of the end effector. As such, the lattice portion 46160 is configured to permit the upper cam members 46140 and the lower cam members 46150, 46210 to flex and/or deflect relative to the body portion 46100 to accommodate lateral forces during the firing stroke.

The body portion 46100 and the lattice portion 46160 can be constructed of varying geometries and materials to accommodate a desired stress profile within the firing member 46000 during the firing stroke. For example, the firing member 46000 can be constructed using 3D printing, or an equivalent process. In at least one embodiment, the body portion 46100 is 3D printed as a unitary piece with the body portion comprising a first material and the lattice portion 46160 comprising a second material that is different from the first material. Further, the first material may comprise a first density and the second material can comprise a second density that is different from the first density.

Further to the above, 3D printing generally produces structures that have some amount of open space (i.e., they are not completely solid on a micro level). As discussed above, the 3D printing process uses a crosshatch or other pattern for interior surfaces housed within more solid wall structures. The density of this pattern within the solid walls is referred to as the infill percentage. The infill percentage can be varied throughout the 3D printing process to produce a component having different infill percentages for different portions of the component. If different infill portions comprise different infill percentages, they inherently comprise different densities on a micro level. In other words, the different infill portions can be varied to produce different micro densities within a component.

Further to the above, other embodiments are envisioned where the infill percentage is uniform throughout the entire part. In such instances, flexibility can be built into the part from macro-geometry aspects, such as slots, cutouts, holes etc. upon which the 3D build is built around. For example, the firing member 46000 may comprise an entirely uniform infill percentage. In such an instance, the slots 46182, 46192 define bar structures in between the slots 46182, 46192, and the bar structures would comprise the same infill percentage as the rest of the firing member 46000, for example.

FIG. 37 depicts a graphical representation 47000 of the forces imparted on the firing member 46000 during a firing stroke. In the illustrated embodiment, the larger the force exerted on the firing member 46000 the darker the shading. The forces are shown in the legend in FIG. 37 as pounds per square inch (PSI). In the illustrated embodiment, a 150 pound load on the distal end of the firing member 46000 resulted in 1 degree of bending during the finite element analysis simulation.

FIGS. 38 and 39 depict a firing member 48000 similar in many aspects to the firing member 46000 and with the differences discussed herein. The firing member 48000 comprises a flexible portion, or lattice portion 48160. The lattice portion 48160 is bifurcated by a longitudinal slot that divides the lattice portion 48160 into a first side 48180 and second side 48190. The first side 48180 comprises a proximal notch 48182 defined in the proximal end of the firing member 48000, and a distal notch 48184 defined in the distal end of the firing member 48000. The notches 48182 and 48184 are V-shaped or triangular cutouts. The proximal notch 48182 is larger along the upper edge, while the distal notch 48184 is larger along the lower edge. The second side 48190 comprises proximal and distal notches that are opposite the proximal notch 48182 and the distal notch 48184. As such, the first side 48180 of the lattice portion 48160 is a flipped mirror image of the second side 48190 of the lattice portion 48160. Similar to the firing member 46000, the firing member 48000 comprises a plurality of slots oriented in the lattice portion 48160. Specifically, the first side 48180 comprises a plurality of slots 48186 oriented in a first direction transverse to longitudinal axis LA of the firing member 48000. Further, the second side 48190 comprises a plurality of slots 48196 oriented transverse to the longitudinal axis LA in a second direction opposite the first direction.

FIG. 40 depicts a model of a flexible portion 49000 configured for use with a firing member of a surgical instrument, such as those firing members described herein. The flexible portion 49000 is configured to flex front-to-back and side-to-side to accommodate a loading force on the firing member during a firing stroke. The flexible portions 44160, 45160, 46160, 48160 described herein can be configured to flex as shown in FIG. 40 , resulting in front-to-back and side-to-side flexing of the I-beam as well. Embodiments are envisioned where the flexible portion 49000 is part of, or takes the place of, the flexible portions 44160, 45160, 46160, 48160 in the firing members described herein. The flexible portion 49000 is configured to transition from a relaxed state 49100 (shown in phantom lines) to a flexed, or deflected state 49100′ (shown in solid lines) when a force is imparted onto the flexible portion 49000.

In the illustrated embodiment, the force applied is imparted onto an upper member 49100 of the flexible member 49000 while a base 49120 of the flexible member 49000 is held stationary. The upper member 49100 and the base 49120 are connected by a first vertical member 49130 and a second vertical member 49140 which crisscross to form an X-configuration. In use, when a force is applied to the upper member 49100, the upper member 49100 transitions to a deflected state 49110′, the first vertical member 49130 transitions to a deflected state 49130′, and the second vertical member 49140 transitions to a deflected state 49140′. The first and second vertical members 49130, 49140 can be deflected to accommodate various loads applied to the upper member 49100.

It should be appreciate that any of the discrete features of the flexible portions 44160, 45160, 46160, 48160, 49000 can be used in combination with each other. For example, the flexible portions 44160 positioned between the upper cam member 44140 and the body portion 44100 may be incorporated into the firing members 45000, 46000, and/or 48000. Moreover, the flexible portions 44160 may be incorporated into any of the lower cam members of firing members 44000, 45000, 46000, 48000, 49000 to provide for greater flexion of the lower cam members in certain instances.

3D printing may be utilized in a similar approach for various instrument components described herein, among others. For example, to accommodate a rotary drive screw in an elongate channel of a surgical instrument, the elongate channel may comprise a distal support bearing or support washer to support the distal end of the rotary drive screw. In at least one embodiment, the distal support bearing could be 3D printed to include a compressible portion that, when compressed in a first direction expands in a second direction that is transverse to the first direction to increase the bearing surface between the distal support bearing and the rotary drive screw. As a result, the coupling between the rotary drive screw and the distal support bearing is improved in certain instances due to a decrease in the bearing loads achieved by increasing the bearing surface area.

Channel retainers and various end effector components are subject to high deflection and longitudinal loads during operation of a surgical instrument. Standard materials for these components consist of aluminum and stainless steel which have limited stretch and deflection capabilities. For example, 250 to 300 pounds of force can be applied longitudinally to a channel retainer during a surgical actuation and an acceptable longitudinal flex can be less than 0.08 inches.

A composite component can include different materials for different portions to obtain complex part geometries, such as interlocking features, alignment keyways, or open sliding passages, for example, with a first material (e.g. plastic) while also maintaining appropriate strength, stiffness, and/or rigidity with a second material (e.g. metal) to support the longitudinal stress and strain loads during a surgical actuation. Metal portion(s) in a composite component can be flexible in one plane but rigid or stiff in another. For example, metal portions can permit lateral flexing but limit longitudinal stretching. Moreover, plastic material can act as a gap filler and interlocking substance between the metal substrates, while also allowing feature-rich, complex geometries. For example, a low durometer or flexible material such as plastic may be used as a body portion for an end effector component. The plastic body portion can comprise metal substrate portions defined therein to bear the loading forces during operation while the plastic body provides keying and alignment features. Such a laminate component can be constructed with 3D printed plastic and metal substrate inserts.

For example, a channel retainer for use with a surgical device can comprise a first metal substrate, a second metal substrate interlocking with the first metal substrate, and a plastic portion built around the first metal substrate and the second metal substrate. The channel retainer is positioned between a handle and an end effector of the surgical device. Further, the channel retainer can comprise alignment and connection features built into the plastic body to facilitate attachment to the surgical device.

FIGS. 41-43 depict a channel retainer 50000 for use with a surgical instrument, such as those described herein. In various embodiments, the proximal end of the channel retainer 50000 can be connected to a handle and/or housing of a surgical instrument and the distal end of the channel retainer 50000 can be connected to an articulation joint and/or end effector of a surgical instrument. The channel retainer 50000 acts as a longitudinal spine portion of the surgical instrument in such instances. Further, the channel retainer 50000 can support articulation actuators, firing actuators, and/or closure actuators of the surgical instrument. In at least one embodiment, the channel retainer 50000 bears the load of a closure tube which surrounds the channel retainer 50000. As the closure tube advances to effectuate an end effector, forces are exerted onto the channel retainer 50000. As such, the channel retainer 50000 can stretch and deflect due to the loading forces exerted by the closure tube.

Further to the above, the proximal end of the channel retainer 50000 comprises notches 50130 which facilitate attachment of the channel retainer 50000 to the handle and/or housing of a surgical instrument. The distal end of the channel retainer 50000 comprises notches 50120 which facilitate attachment of the channel retainer to an articulation joint and/or end effector of a surgical instrument. However, other embodiments are envisioned with different attachment features for connecting the channel retainer 50000 to the surgical instrument.

Further to the above, the channel retainer 50000 comprises a body portion 50100, first substrate portions 50300, and second substrate portions 50400. The channel retainer 50000 further comprises a longitudinal slot 50110 defined therein for receiving various actuators of a surgical instrument. For example, a firing member extending from a handle or housing of a surgical instrument can extend within the longitudinal slot 50110. In any event, the longitudinal slot 50110 splits the channel retainer 50000 in half with the first and second substrate portion 50300, 50400 positioned on each side of the slot 50110 (i.e., the channel retainer 50000 is symmetrical). In at least one embodiment, the body portion 50100 is 3D printed with the first and second substrate portions 50300, 50400 defined therein. In other words, the body portion 50100 is built around the first and second substrate portions 50300, 50400. In at least one embodiment, the body portion 50100 is comprised of plastic and the substrate portions 50300, 50400 are comprised of metal. The substrate portions 50300, 50400 can be comprised of stamped metal plates, for example. Other embodiments are envisioned where the substrate portions 50300, 50400 comprises materials that are more rigid and/or dense than the body portion 50100, for example.

As illustrated in FIG. 43 , the first substrate portions 50300 are positioned within the body portion 50110 at the proximal end. Each first substrate portion 50300 comprises a first lateral flange 50310 at its distal end. The first lateral flanges 50310 extend toward the longitudinal slot 50110. The second substrate portions 50400 are positioned within the body portion 50100 and each comprises a first opening 50410 at their proximal end and a second opening 50420 at their distal end. The first and second substrates 50300, 50400 are positioned such that the first opening 50410 receives the first lateral flange 50310 to operably connect the first substrate portion 50200 and the second substrate portion 50400 within the body portion 50100. In other words, the first and second substrate portions 50300, 50400 are at least partially embedded and/or encapsulated within the body portion 50100.

These substrates can form a multi-interlocking load sharing assembly comprised of stamped components within the 3D-printed assembly. In certain instances, interlocking of stamped components within a 3D-printed assembly can be utilized to combine components where injection molding is not a viable alternative due to the shrinking of the composite material over elongated metal components during a molding process, which can result in a buildup of internal stresses and shear features within the assembly. For example, elongate assemblies, such as channel retainers, for example, may be better suited to 3D printing around interlocking metal components.

Further to the above, each of the first substrate portions 50300 comprise a second lateral flange 50320 positioned at their proximal end and extending away from the longitudinal slot 50110. The second lateral flanges 50320 are built and/or embedded into the body portion 50100 such that they extend behind the proximal notches 50310 defined in the body portion 50100. As such, the first substrate portions 50300 are at least partially restricted from moving longitudinally within the body portion 50100 due to their engagement with the proximal notches 50310. Further, the alignment notches 50310 may be used to attach and align the channel retainer 50000 within a handle or housing of the surgical instrument. As such, the first substrate portions 50300 within the proximal end provide additional support to the channel retainer 50000 to facilitate attachment to a surgical instrument. Other embodiments are envisioned with the first substrate portions 50300 at both the proximal and distal ends to facilitate attachment to a surgical device. In at least one embodiment, the body portion 50100 comprises a keying feature, an alignment feature, and/or an interlocking feature for use with a surgical instrument.

The first and second substrate portions 50300, 50400 can comprise more rigid metallic materials to bear the loading and stretch forces that the channel retainer 50000 experiences during operation of the surgical instrument.

Further to the above, the first substrate portion 50300 and/or the second substrate portion 50400 comprise flexible circuit boards and/or other integrated electronics supported or affixed thereto. During manufacture, the 3D printing material of the body portion 50100 can be overprinted around the substrate portions 50300, 50400 without directly affixing the build material to the electronics of the substrate portions 50300, 50400. By preventing direct application of the 3D build material onto the substrate portions 50300, 50400, the risk of damage to the substrate portions 50300, 50400 and their electronic components is reduced. For example, referring primarily to FIG. 43 , there are various gaps 50500 between the substrate portions 50300, 50400 and the body portion 50100. As such, the channel retainer 50000 is constructed such that at least portions of the substrate portions 50300, 50400 are not 3D printed directly thereon. Electronic components can be positioned in locations that are not directly 3D printed on, which can inhibit heat transfer and/or inadvertent damage to the electronic components due to localized heat. However, other embodiments are envisioned where the substrate portions 50300, 50400 are completely encapsulated and surrounded by the 3D build material of the body portion 50100.

As discussed above, the channel retainer 50000 may be constructed via 3D printing. For example, before the 3D build begins, metal substrates such as substrate portions 50300, are introduced upon which the 3D plastic build will be attached. Partially through the 3D build, the build could be stopped with standing alignment features to permit the creation of a perimeter build flange. The perimeter build flange allows for the introduction of another mid-substance metallic support plate, or substrate portions 50400, for example. In at least one embodiment, the substrate portions 50300, 50400 can be aligned in such a manner as to have coupling plastic features (such as notches 50130, for example) that prevent movement of the substrates 50300, 50400 within the body portion 50100 while also preventing shear of the body portion 50100. In at least one embodiment, the channel retainer 50000 is a sandwiched laminate comprised of metal plates with 3D plastic printed coupling and assembly features. The metal plates are capable of bearing the load and stretch properties and the 3D printed elements are configured to provide all the keying, aligning, lateral support, and interlocking features with adjacent systems. 3D printing a channel retainer in this manner enables complex plastic interface features to be affixed to load bearing metallic sub-frames within and around the 3D built part.

Further to the above, a steel stamped part could have a lateral flange bend in both ends for affixing to an elongate shaft and/or an articulation joint of a surgical instrument. The flanges could be laid into the 3D printer with the flanges away from the printing head path. The 3D build is then continued to form the rest of the channel retainer. As such, the lateral flange bends extend from the 3D printed channel retainer for attachment to the surgical instrument. In other words, the lateral flange bends are not overprinted with 3D printing material, extend from the 3D printed material, and are attachable to the surgical instrument.

Further to the above, other embodiments are envisioned with a 3D printed laminate construction comprising a plastic body and metal substrates for various end effector components. For example, a staple cartridge, an elongate channel configured to receive a staple cartridge, and/or an anvil, could be constructed as a 3D printed laminate with plastic and metallic materials. As such, embodiments are envisioned where other end effector components utilize a plastic body for all of the keying and alignment features while the metal substrates bear the stretch and deflection loads during operation.

Further to the above, with traditional insert molded parts creating undercuts, interior voids, interior spaces, and/or features transverse to the parting line of the mold (.e. more than 3 degrees from the parting axis of the mold) may be difficult and costly to manufacture in certain instances. The 3D-printed plastic body discussed above, can comprise undercuts, interior voids, and/or transverse alignment features for connecting components, for example.

FIGS. 44 and 45 depict a surgical instrument 51000 comprising a firing bar support 51020, a firing bar 51010, and an over-molded sleeve 51030. The firing bar support 51020 comprises two lateral plates 51022, 51024 positioned on both sides of the firing bar 51010. In the illustrated embodiment, the firing bar 51010 comprises a laminate firing bar constructed of several layers. Other embodiments are envisioned where the firing bar is a one-piece unitary structure. In any event, the firing bar support 51020 prevents bucking of the firing bar 51010 during firing of the firing bar 51010 and/or articulation of the end effector 51000. In certain instances, the firing bar support 51020 may be identical to the firing bar support disclosed in U.S. patent application Ser. No. 15/635,808 filed on Jun. 28, 2017, the entirety of which is incorporated by reference herein. Further, the firing bar support 51020 comprises a flexible portion 51040 positioned in an articulation joint of the surgical instrument 51000. Specifically, FIG. 44 illustrates the surgical instrument 51000 in an unarticulated orientation and FIG. 45 illustrates the surgical instrument 51000 in an articulated configuration.

The firing bar support 51020 is defined within the over-molded sleeve 51030 that extends along the articulation joint of the surgical instrument 51000. In other words, the over-molded sleeve 51030 encompasses and/or encapsulates the firing bar support 51020 therein. In at least one embodiment, the over-molded sleeve 51030 may be a plastic 3D printed material built around the firing bar support 51020 to embed and/or encapsulate the firing bar support 51020 therein. As such, the over-molded sleeve 51030 and the firing bar support 51020 comprise a substantially unitary piece. Further, the unitary piece formed of the over-molded sleeve 51030 and the firing bar support 51030 comprises a longitudinal slot 51032 defined therein. The longitudinal slot 51032 is configured to receiving the firing bar 51010 to permit translation of the firing member 51010 therein.

FIG. 46 depicts an anvil 52000 for use with a surgical instrument, such as those described herein. The anvil 52000 comprises a tissue contacting surface 52020 and a longitudinal slot 52030 for receiving a portion of a firing member. The anvil 52000 further comprises an anvil slot 52040 extending longitudinally along at least a portion of the anvil 52000. In the illustrated embodiment, the anvil slot 52040 is plus-shaped, however, other embodiments are envisioned where the anvil slot 52040 is T-shaped with a flat top portion. The reader will appreciate that alternative geometries and shapes for the anvil slot 52040 are contemplated. In any event, the anvil 52000 comprises a compliant portion 52050 extending longitudinally along at least a portion of the anvil slot 52040. In the illustrated embodiment, the compliant portion 52050 is positioned around the perimeter of the anvil slot 52040 on all sides. However, other embodiments are envisioned where the compliant portion 52050 resides solely on a pair of anvil slot ledges 52060 of the anvil 52000.

In at least one embodiment, the compliant portion 52050 comprises a more compressible material than the remainder of the anvil 52000. For example, the compliant portion 52050 can comprise a material that is less dense or softer (i.e., a smaller number on Mohs hardness scale) than the remainder of anvil 52000 material. In at least one embodiment, the compliant portion 52050 can be comprised of brass or bronze and the remainder of the anvil 52000 can be comprised of stainless steel. In any event, the upper pins or upper cam members of a firing member (i.e., an I-beam or E-beam) can ride along the compliant portion 52050 during firing. As such, the body of the anvil 52000 is more rigid with the anvil slot 52040 being softer and/or more compliant to facilitate more give to the firing member during firing. Further, the compliant portion 52050 may be smoother than the remainder of the anvil 52000 to further facilitate sliding of the upper pins of the firing member within the anvil slot 52040.

Further to the above, the anvil 52000 may be constructed using 3D printing to position the compliant portion 52050 within the body of the anvil 52000. For example, the 3D printer could begin by building up stainless steel from the tissue contacting surface 52020 upward. The 3D build could be stopped to insert the compliant member 52050, and then the build continued to encapsulate the compliant member 52050 within the stainless steel 3D print material of the anvil 52000. As such, the compliant member 52050 and the anvil 52000 can be 3D printed to produce a substantially unitary piece having two different materials. Other embodiments are envisioned with more than two materials 3D printed into the anvil 52000.

Various aspects of the subject matter described herein are set out in the following examples.

Example 1—A firing member for use with a surgical instrument comprising an anvil and an elongate channel configured to receive a staple cartridge. The firing member comprises a body portion configured to be driven through a firing stroke, a first cam member extending laterally from the body portion and configured to cammingly engage the anvil during the firing stroke, a second cam member extending laterally from the body portion and configured to cammingly engage the elongate channel during the firing stroke, and a lattice portion comprising a pattern of spaces formed in the firing member. The lattice portion is configured to flex more readily from a load during the firing stroke than adjacent portions of the firing member.

Example 2—The firing member of Example 1, wherein the lattice portion is positioned intermediate the first cam member and the second cam member.

Example 3—The firing member of Examples 1 or 2, further comprising a longitudinal slot extending longitudinally through the firing member, wherein the longitudinal slot bifurcates the lattice portion into a first portion on a first side of the longitudinal slot and a second portion on a second side of the longitudinal slot, and wherein the lattice portion is configured to deflect in opposing directions on opposite sides of the longitudinal slot.

Example 4—The firing member of Example 3, wherein the pattern of spaces comprises a first plurality of slots in the first portion and a second plurality of slots in the second portion.

Example 5—The firing member of Example 4, wherein the first plurality of slots are oriented in a first direction, and wherein the second plurality of slots are oriented in a second direction opposite the first direction.

Example 6—The firing member of Examples 4 or 5, wherein the first plurality of slots are parallel to one another, and wherein the second plurality of slots are parallel to one another.

Example 7—The firing member of Examples 1, 2, 3, 4, 5, or 6, wherein the lattice portion connects at least a portion of the first cam member to the body portion.

Example 8—The firing member of Examples 1, 2, 3, 4, 5, 6, or 7, wherein the pattern of spaces define a plurality of arcuate bars connecting the first cam member and the body portion.

Example 9—The firing member of Example 8, wherein the plurality of arcuate bars are arranged in an array.

Example 10—The firing member of Examples 1, 2, 3, 4, 5, 6, 7, 8, or 9, wherein the pattern of spaces comprises an array of crisscrossing diagonal slots.

Example 11—The firing member of Examples 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10, wherein the lattice portion is less rigid than the first cam member and the body portion.

Example 12—An end effector comprising an anvil, an elongate channel configured to receive a staple cartridge, and a firing member. The firing member comprises a body portion, a first cam member extending laterally from the body portion and configured to cammingly engage the anvil during a firing stroke of the firing member, a second cam member extending laterally from the body portion and configured to cammingly engage the elongate channel during the firing stroke, and a flexible portion positioned intermediate the first cam member and the body portion. The flexible portion comprises a three-dimensional lattice comprising an array of cavities.

Example 13—The end effector of Example 12, wherein the array of cavities define a plurality of arcuate bars.

Example 14—The end effector of Examples 12 or 13, wherein the flexible portion comprises a first rigidity, wherein the body portion and the first cam member comprise a second rigidity, and wherein the first rigidity and the second rigidity are different.

Example 15—A firing member for use with a surgical instrument comprising a first jaw and a second jaw. The firing member comprises a body portion configured to move longitudinally through a firing stroke, a first cam member extending laterally from the body portion and configured to cammingly engage the first jaw during the firing stroke, a second cam member extending laterally from the body portion and configured to cammingly engage the second jaw during the firing stroke, and a low density portion comprising a flexible lattice configured to flex more readily from a load during the firing stroke than adjacent portions of the firing member.

Example 16—The firing member of Example 15, wherein the flexible lattice deflects a first amount when the first cam member is under the load, wherein the body portion adjacent the flexible lattice deflects a second amount when the first cam member is under the load, and wherein the first amount is greater than the second amount.

Example 17—The firing member of Examples 15 or 16, wherein the body portion comprises a first rigidity, wherein the flexible lattice comprises a second rigidity, and wherein the first rigidity and the second rigidity are different.

Example 18—The firing member of Examples 15, 16, or 17, wherein the flexible lattice comprises a plurality of slots arranged in a pattern and defined in the body portion.

Example 19—The firing member of Examples 15, 16, 17, or 18, wherein the body portion comprises a first infill percentage, wherein the low density portion comprises a second infill percentage, and wherein the first infill percentage and the second infill percentage are different.

Example 20—The firing member of Examples 15, 16, 17, 18, or 19, further comprising a longitudinal slot extending longitudinally through the firing member, wherein the longitudinal slot bifurcates the flexible lattice into a first portion on a first side of the longitudinal slot and a second portion on a second side of the longitudinal slot.

Example 21—The firing member of Example 20, wherein the first portion comprises a plurality of slots oriented in a first direction and the second portion comprises a plurality of slots oriented in a second direction that is opposite the first direction.

Example 22—A firing member for use with a surgical instrument comprising an anvil and an elongate channel configured to receive a staple cartridge, wherein the firing member comprises a body portion configured to be driven through a firing stroke, a first cam member extending laterally from the body portion and configured to cammingly engage the anvil during the firing stroke, a second cam member extending laterally from the body portion and configured to cammingly engage the elongate channel during the firing stroke, and a flexible portion. The flexible portion comprises a pattern of spaces formed in the firing member. The flexible portion is configured to flex more readily from a load during the firing stroke than adjacent less flexible portions of the firing member. The flexible portion is the same material as the adjacent less flexible portions.

Example 23—A channel retainer for use with a surgical device. The channel retainer is positionable between a handle and an end effector of the surgical device. The channel retainer comprises a proximal end, a distal end, a plastic body extending from the proximal end to the distal end, a first metal substrate positioned within the plastic body, and a second metal substrate positioned within the plastic body. The first metal substrate comprises a lateral flange. The second metal substrate comprises an opening. The lateral flange is positioned within the opening to operably connect the first metal substrate and the second metal substrate within the plastic body.

Example 24—The channel retainer of Example 23, wherein the first metal substrate is positioned at the proximal end of the channel retainer, and wherein the proximal end of the channel retainer is configured to be attached to the handle of the surgical device.

Example 25—The channel retainer of Examples 23 or 24, wherein the plastic body comprises an alignment notch, and wherein the first metal substrate comprises another lateral flange embedded in the plastic body proximal to the alignment notch.

Example 26—The channel retainer of Examples 23, 24, or 25, wherein at least one of the first metal substrate and the second metal substrate comprises a stamped metal component.

Example 27—The channel retainer of Examples 23, 24, 25, or 26, wherein the plastic body is printed on the first metal substrate and the second metal substrate.

Example 28—The channel retainer of Examples 23, 24, 25, 26, or 27, wherein the plastic body comprises one of a group consisting of a keying feature, an alignment feature, and an interlocking feature for connection with the surgical device.

Example 29—The channel retainer of Examples 23, 24, 25, 26, 27, or 28, wherein at least one of the first metal substrate and the second metal substrate comprises a flexible circuit board.

Example 30—A channel retainer for use with a surgical device. The channel retainer comprises a proximal end, a distal end, a first metal substrate, a second metal substrate interlocking with the first metal substrate, and a plastic portion extending from the proximal end to the distal end. The plastic portion is built around the first metal substrate and the second metal substrate.

Example 31—The channel retainer of Example 30, wherein the first metal substrate comprises a flange embedded in an alignment portion of the plastic portion, and wherein the alignment portion is configured to attach the plastic portion to the surgical device.

Example 32—The channel retainer of Examples 30 or 31, wherein the plastic portion comprises an alignment notch, and wherein the first metal substrate comprises a lateral flange embedded in the plastic portion proximal to the alignment notch.

Example 33—The channel retainer of Examples 30, 31, or 32, wherein at least one of the first metal substrate and the second metal substrate comprises a stamped metal component.

Example 34—The channel retainer of Examples 30, 31, 32, or 33, wherein the plastic portion is printed on the first metal substrate and the second metal substrate.

Example 35—The channel retainer of Examples 30, 31, 32, 33, or 34, wherein the plastic portion comprises one of a group consisting of a keying feature, an aligning feature, and an interlocking feature for connection with the surgical device.

Example 36—The channel retainer of Examples 30, 31, 32, 33, 34, or 35, wherein at least one of the first metal substrate and the second metal substrate comprises a flexible circuit board.

Example 37—An end effector component for use with a surgical stapling device. The end effector component comprises a plastic body comprising alignment features. The end effector component further comprises a first metal substrate at least partially surrounded by the plastic body. The end effector component further comprises a second metal substrate at least partially surrounded by the plastic body. The first metal substrate and the second metal substrate comprise substrate interlocking features embedded within the plastic body.

Example 38—The end effector component of Example 37, wherein the first metal substrate comprise a lateral flange, wherein the second metal substrate comprises an opening, and wherein the lateral flange is positioned within the opening and surrounded by the plastic body.

Example 39—The end effector component of Examples 37 or 38, wherein the alignment features comprise notches at a proximal and a distal end of the plastic body, and wherein the notches facilitate attachment and alignment of the end effector component to a handle and an end effector of the surgical stapling device.

Example 40—The end effector component of Examples 37, 38, or 39, wherein the end effector component comprises an elongate channel configured to receive a staple cartridge.

Example 41—The end effector component of Examples 37, 38, 39, or 40, wherein at least one of the first metal substrate and the second metal substrate comprises a flexible circuit board.

Example 42—The end effector component of Examples 37, 38, 39, 40, or 41 wherein the plastic body comprises an interior void, and wherein the interior void is completely surrounded by the plastic body.

Example 43—The end effector component of Examples 37, 38, 39, 40, 41, or 42, wherein the plastic body comprises an undercut.

Many of the surgical instrument systems described herein are motivated by an electric motor; however, the surgical instrument systems described herein can be motivated in any suitable manner. In various instances, the surgical instrument systems described herein can be motivated by a manually-operated trigger, for example. In certain instances, the motors disclosed herein may comprise a portion or portions of a robotically controlled system. Moreover, any of the end effectors and/or tool assemblies disclosed herein can be utilized with a robotic surgical instrument system. U.S. patent application Ser. No. 13/118,241, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S. Pat. No. 9,072,535, for example, discloses several examples of a robotic surgical instrument system in greater detail.

The surgical instrument systems described herein have been described in connection with the deployment and deformation of staples; however, the embodiments described herein are not so limited. Various embodiments are envisioned which deploy fasteners other than staples, such as clamps or tacks, for example. Moreover, various embodiments are envisioned which utilize any suitable means for sealing tissue. For instance, an end effector in accordance with various embodiments can comprise electrodes configured to heat and seal the tissue. Also, for instance, an end effector in accordance with certain embodiments can apply vibrational energy to seal the tissue.

The entire disclosures of:

U.S. Pat. No. 5,403,312, entitled ELECTROSURGICAL HEMOSTATIC DEVICE, which issued on Apr. 4, 1995;

U.S. Pat. No. 7,000,818, entitled SURGICAL STAPLING INSTRUMENT HAVING SEPARATE DISTINCT CLOSING AND FIRING SYSTEMS, which issued on Feb. 21, 2006;

U.S. Pat. No. 7,422,139, entitled MOTOR-DRIVEN SURGICAL CUTTING AND FASTENING INSTRUMENT WITH TACTILE POSITION FEEDBACK, which issued on Sep. 9, 2008;

U.S. Pat. No. 7,464,849, entitled ELECTRO-MECHANICAL SURGICAL INSTRUMENT WITH CLOSURE SYSTEM AND ANVIL ALIGNMENT COMPONENTS, which issued on Dec. 16, 2008;

U.S. Pat. No. 7,670,334, entitled SURGICAL INSTRUMENT HAVING AN ARTICULATING END EFFECTOR, which issued on Mar. 2, 2010;

U.S. Pat. No. 7,753,245, entitled SURGICAL STAPLING INSTRUMENTS, which issued on Jul. 13, 2010;

U.S. Pat. No. 8,393,514, entitled SELECTIVELY ORIENTABLE IMPLANTABLE FASTENER CARTRIDGE, which issued on Mar. 12, 2013;

U.S. patent application Ser. No. 11/343,803, entitled SURGICAL INSTRUMENT HAVING RECORDING CAPABILITIES, now U.S. Pat. No. 7,845,537;

U.S. patent application Ser. No. 12/031,573, entitled SURGICAL CUTTING AND FASTENING INSTRUMENT HAVING RF ELECTRODES, filed Feb. 14, 2008;

U.S. patent application Ser. No. 12/031,873, entitled END EFFECTORS FOR A SURGICAL CUTTING AND STAPLING INSTRUMENT, filed Feb. 15, 2008, now U.S. Pat. No. 7,980,443;

U.S. patent application Ser. No. 12/235,782, entitled MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT, now U.S. Pat. No. 8,210,411;

U.S. patent application Ser. No. 12/249,117, entitled POWERED SURGICAL CUTTING AND STAPLING APPARATUS WITH MANUALLY RETRACTABLE FIRING SYSTEM, now U.S. Pat. No. 8,608,045;

U.S. patent application Ser. No. 12/647,100, entitled MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT WITH ELECTRIC ACTUATOR DIRECTIONAL CONTROL ASSEMBLY, filed Dec. 24, 2009, now U.S. Pat. No. 8,220,688;

U.S. patent application Ser. No. 12/893,461, entitled STAPLE CARTRIDGE, filed Sep. 29, 2012, now U.S. Pat. No. 8,733,613;

U.S. patent application Ser. No. 13/036,647, entitled SURGICAL STAPLING INSTRUMENT, filed Feb. 28, 2011, now U.S. Pat. No. 8,561,870;

U.S. patent application Ser. No. 13/118,241, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S. Pat. No. 9,072,535;

U.S. patent application Ser. No. 13/524,049, entitled ARTICULATABLE SURGICAL INSTRUMENT COMPRISING A FIRING DRIVE, filed on Jun. 15, 2012, now U.S. Pat. No. 9,101,358;

U.S. patent application Ser. No. 13/800,025, entitled STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013, now U.S. Pat. No. 9,345,481;

U.S. patent application Ser. No. 13/800,067, entitled STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013, now U.S. Patent Application Publication No. 2014/0263552;

U.S. Patent Application Publication No. 2007/0175955, entitled SURGICAL CUTTING AND FASTENING INSTRUMENT WITH CLOSURE TRIGGER LOCKING MECHANISM, filed Jan. 31, 2006; and

U.S. Patent Application Publication No. 2010/0264194, entitled SURGICAL STAPLING INSTRUMENT WITH AN ARTICULATABLE END EFFECTOR, filed Apr. 22, 2010, now U.S. Pat. No. 8,308,040, are hereby incorporated by reference herein.

Although various devices have been described herein in connection with certain embodiments, modifications and variations to those embodiments may be implemented. Particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Thus, the particular features, structures, or characteristics illustrated or described in connection with one embodiment may be combined in whole or in part, with the features, structures or characteristics of one or more other embodiments without limitation. Also, where materials are disclosed for certain components, other materials may be used. Furthermore, according to various embodiments, a single component may be replaced by multiple components, and multiple components may be replaced by a single component, to perform a given function or functions. The foregoing description and following claims are intended to cover all such modification and variations.

The devices disclosed herein can be designed to be disposed of after a single use, or they can be designed to be used multiple times. In either case, however, a device can be reconditioned for reuse after at least one use. Reconditioning can include any combination of the steps including, but not limited to, the disassembly of the device, followed by cleaning or replacement of particular pieces of the device, and subsequent reassembly of the device. In particular, a reconditioning facility and/or surgical team can disassemble a device and, after cleaning and/or replacing particular parts of the device, the device can be reassembled for subsequent use. Those skilled in the art will appreciate that reconditioning of a device can utilize a variety of techniques for disassembly, cleaning/replacement, and reassembly. Use of such techniques, and the resulting reconditioned device, are all within the scope of the present application.

The devices disclosed herein may be processed before surgery. First, a new or used instrument may be obtained and, when necessary, cleaned. The instrument may then be sterilized. In one sterilization technique, the instrument is placed in a closed and sealed container, such as a plastic or TYVEK bag. The container and instrument may then be placed in a field of radiation that can penetrate the container, such as gamma radiation, x-rays, and/or high-energy electrons. The radiation may kill bacteria on the instrument and in the container. The sterilized instrument may then be stored in the sterile container. The sealed container may keep the instrument sterile until it is opened in a medical facility. A device may also be sterilized using any other technique known in the art, including but not limited to beta radiation, gamma radiation, ethylene oxide, plasma peroxide, and/or steam.

While this invention has been described as having exemplary designs, the present invention may be further modified within the spirit and scope of the disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles.

Any patent, publication, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated materials do not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material. 

What is claimed is:
 1. A channel retainer for use with a surgical device, wherein the channel retainer is positionable between a handle and an end effector of the surgical device, and wherein the channel retainer comprises: a proximal end; a distal end; a plastic body extending from the proximal end to the distal end; a first metal substrate positioned within the plastic body, wherein the first metal substrate comprises a lateral flange; and a second metal substrate positioned within the plastic body, wherein the second metal substrate comprises an opening, and wherein the lateral flange is positioned within the opening to operably connect the first metal substrate and the second metal substrate within the plastic body.
 2. The channel retainer of claim 1, wherein the first metal substrate is positioned at the proximal end of the channel retainer, and wherein the proximal end of the channel retainer is configured to be attached to the handle of the surgical device.
 3. The channel retainer of claim 1, wherein the plastic body comprises an alignment notch, and wherein the first metal substrate comprises another lateral flange embedded in the plastic body proximal to the alignment notch.
 4. The channel retainer of claim 1, wherein at least one of the first metal substrate and the second metal substrate comprises a stamped metal component.
 5. The channel retainer of claim 1, wherein the plastic body is printed on the first metal substrate and the second metal substrate.
 6. The channel retainer of claim 1, wherein the plastic body comprises one of a group consisting of a keying feature, an alignment feature, and an interlocking feature for connection with the surgical device.
 7. The channel retainer of claim 1, wherein at least one of the first metal substrate and the second metal substrate comprises a flexible circuit board.
 8. A channel retainer for use with a surgical device, wherein the channel retainer comprises: a proximal end; a distal end; a first metal substrate; a second metal substrate interlocking with the first metal substrate; and a plastic portion extending from the proximal end to the distal end, wherein the plastic portion is built around the first metal substrate and the second metal substrate.
 9. The channel retainer of claim 8, wherein the first metal substrate comprises a flange embedded in an alignment portion of the plastic portion, and wherein the alignment portion is configured to attach the plastic portion to the surgical device.
 10. The channel retainer of claim 8, wherein the plastic portion comprises an alignment notch, and wherein the first metal substrate comprises a lateral flange embedded in the plastic portion proximal to the alignment notch.
 11. The channel retainer of claim 8, wherein at least one of the first metal substrate and the second metal substrate comprises a stamped metal component.
 12. The channel retainer of claim 8, wherein the plastic portion is printed on the first metal substrate and the second metal substrate.
 13. The channel retainer of claim 8, wherein the plastic portion comprises one of a group consisting of a keying feature, an aligning feature, and an interlocking feature for connection with the surgical device.
 14. The channel retainer of claim 8, wherein at least one of the first metal substrate and the second metal substrate comprises a flexible circuit board.
 15. An end effector component for use with a surgical stapling device, wherein the end effector component comprises: a plastic body comprising alignment features; a first metal substrate at least partially surrounded by the plastic body; and a second metal substrate at least partially surrounded by the plastic body, wherein the first metal substrate and the second metal substrate comprise substrate interlocking features embedded within the plastic body.
 16. The end effector component of claim 15, wherein the first metal substrate comprise a lateral flange, wherein the second metal substrate comprises an opening, and wherein the lateral flange is positioned within the opening and surrounded by the plastic body.
 17. The end effector component of claim 15, wherein the alignment features comprise notches at a proximal and a distal end of the plastic body, and wherein the notches facilitate attachment and alignment of the end effector component to a handle and an end effector of the surgical stapling device.
 18. The end effector component of claim 15, wherein the end effector component comprises an elongate channel configured to receive a staple cartridge.
 19. The end effector component of claim 15, wherein at least one of the first metal substrate and the second metal substrate comprises a flexible circuit board.
 20. The end effector component of claim 15, wherein the plastic body comprises an interior void, and wherein the interior void is completely surrounded by the plastic body.
 21. The end effector component of claim 15, wherein the plastic body comprises an undercut.
 22. A channel retainer for use with a surgical device, wherein the channel retainer comprises: a plastic body; a first metal substrate embedded within the plastic body; and a second metal substrate embedded within the plastic body and interlocking with the first metal substrate.
 23. The channel retainer of claim 22, wherein: the first metal substrate comprises a first lateral flange; and the second metal substrate defines an opening, and wherein the first lateral flange is received within the opening.
 24. The channel retainer of claim 23, further comprising a longitudinal slot configured to receive an actuator of the surgical device.
 25. The channel retainer of claim 24, wherein the longitudinal slot defines a longitudinal axis, and wherein the channel retainer is symmetrical about the longitudinal axis.
 26. The channel retainer of claim 24, wherein the first metal substrate further comprises a second lateral flange, wherein the first lateral flange extends toward the longitudinal slot, and wherein the second lateral flange extends away from the longitudinal slot.
 27. The channel retainer of claim 26, wherein the plastic body comprises an alignment notch, and wherein the second lateral flange is positioned proximal to the alignment notch.
 28. The channel retainer of claim 22, wherein the first metal substrate is positioned at a proximal end of the channel retainer, and wherein the proximal end of the channel retainer is configured to be attached to a housing of the surgical device.
 29. The channel retainer of claim 22, wherein at least one of the first metal substrate and the second metal substrate comprises a stamped metal component.
 30. The channel retainer of claim 22, wherein the plastic body is printed on the first metal substrate and the second metal substrate.
 31. The channel retainer of claim 22, wherein the plastic body comprises one of a group consisting of a keying feature, an alignment feature, and an interlocking feature for connection with the surgical device.
 32. The channel retainer of claim 22, wherein at least one of the first metal substrate and the second metal substrate comprises a flexible circuit board. 